EB welding of launch vehicles

NASA Astrophysics Data System (ADS)

Szabo, Attila

While large structural components can be electron beam (EB) welded, equipment and operating costs increase with the requisite vacuum chamber's size. Attention is presently given to cost-effective ways of EB welding launch-vehicle assemblies without compromise of weld quality in such alloys as 2219, 2090, Weldalite, and HP9-4-30/20. Weld strengths at both room and cryogenic temperatures that were 50 percent higher than those obtainable for such materials with arc welding have been demonstrated. Fracture toughnesses were also 40-50 percent higher than arc-welded values. Attention is given to EB joint fit-up allowables for 2219-T87 Al alloy.

Electron Beam Welding to Join Gamma Titanium Aluminide Articles

NASA Technical Reports Server (NTRS)

Kelly, Thomas Joseph (Inventor)

2008-01-01

A method is provided for welding two gamma titanium aluminide articles together. The method includes preheating the two articles to a welding temperature of from about 1700 F to about 2100 F, thereafter electron beam welding the two articles together at the welding temperature and in a welding vacuum to form a welded structure, and thereafter annealing the welded structure at an annealing temperature of from about 1800 F to about 2200 F, to form a joined structure.

Welding Experiments of Aluminum Alloy by Space GHTA Welding in the ISS Orbital Pressure

NASA Astrophysics Data System (ADS)

Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

As a feasible welding method in space, the authors have previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. The space GHTA welding with high frequency power source for the arc starting may cause the electro-magnetic noise problems of computer equipments placed on the ISS. Therefore, in this paper the welding experiments of aluminum alloy by the space GHTA welding with DC high voltage power source for the arc starting was carried out in the ISS orbital pressure 10-5Pa. It is made clear that there is the shifting phenomenon in which the spark discharge changes to the glow or arc discharge at starting phenomenon of the space GHTA welding in high vacuum condition, and the features of those starting phenomenon are demonstrated. And the space GHTA welding with DC high voltage power source can be used for welding in the ISS orbital pressure.

Vacuum Brazing of Accelerator Components

NASA Astrophysics Data System (ADS)

Singh, Rajvir; Pant, K. K.; Lal, Shankar; Yadav, D. P.; Garg, S. R.; Raghuvanshi, V. K.; Mundra, G.

2012-11-01

Commonly used materials for accelerator components are those which are vacuum compatible and thermally conductive. Stainless steel, aluminum and copper are common among them. Stainless steel is a poor heat conductor and not very common in use where good thermal conductivity is required. Aluminum and copper and their alloys meet the above requirements and are frequently used for the above purpose. The accelerator components made of aluminum and its alloys using welding process have become a common practice now a days. It is mandatory to use copper and its other grades in RF devices required for accelerators. Beam line and Front End components of the accelerators are fabricated from stainless steel and OFHC copper. Fabrication of components made of copper using welding process is very difficult and in most of the cases it is impossible. Fabrication and joining in such cases is possible using brazing process especially under vacuum and inert gas atmosphere. Several accelerator components have been vacuum brazed for Indus projects at Raja Ramanna Centre for Advanced Technology (RRCAT), Indore using vacuum brazing facility available at RRCAT, Indore. This paper presents details regarding development of the above mentioned high value and strategic components/assemblies. It will include basics required for vacuum brazing, details of vacuum brazing facility, joint design, fixturing of the jobs, selection of filler alloys, optimization of brazing parameters so as to obtain high quality brazed joints, brief description of vacuum brazed accelerator components etc.

Vacuum encapsulated, high temperature diamond amplified cathode capsule and method for making same

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rao, Triveni; Walsh, Josh; Gangone, Elizabeth

2015-12-29

A vacuum encapsulated, hermetically sealed cathode capsule for generating an electron beam of secondary electrons, which generally includes a cathode element having a primary emission surface adapted to emit primary electrons, an annular insulating spacer, a diamond window element comprising a diamond material and having a secondary emission surface adapted to emit secondary electrons in response to primary electrons impinging on the diamond window element, a first high-temperature solder weld disposed between the diamond window element and the annular insulating spacer and a second high-temperature solder weld disposed between the annular insulating spacer and the cathode element. The cathode capsulemore » is formed by a high temperature weld process under vacuum such that the first solder weld forms a hermetical seal between the diamond window element and the annular insulating spacer and the second solder weld forms a hermetical seal between the annular spacer and the cathode element whereby a vacuum encapsulated chamber is formed within the capsule.« less

Vacuum encapsulated hermetically sealed diamond amplified cathode capsule and method for making same

DOEpatents

Rao, Triveni; Walsh, John; Gangone, Elizabeth

2014-12-30

A vacuum encapsulated, hermetically sealed cathode capsule for generating an electron beam of secondary electrons, which generally includes a cathode element having a primary emission surface adapted to emit primary electrons, an annular insulating spacer, a diamond window element comprising a diamond material and having a secondary emission surface adapted to emit secondary electrons in response to primary electrons impinging on the diamond window element, a first cold-weld ring disposed between the cathode element and the annular insulating spacer and a second cold-weld ring disposed between the annular insulating spacer and the diamond window element. The cathode capsule is formed by a vacuum cold-weld process such that the first cold-weld ring forms a hermetical seal between the cathode element and the annular insulating spacer and the second cold-weld ring forms a hermetical seal between the annular spacer and the diamond window element whereby a vacuum encapsulated chamber is formed within the capsule.

Welding Experiments of Aluminum Alloy by Space GHTA Welding at ISS Orbital Pressure

NASA Astrophysics Data System (ADS)

Suita, Yoshikazu; Takai, Daisuke; Sugiyama, Satoshi; Terajima, Noboru; Tsukuda, Yoshiyuki; Fujisawa, Shoichiro; Imagawa, Kichiro

As a feasible welding method in space, the authors previously proposed the space GHTA (Gas Hollow Tungsten Arc) welding process. However, space GHTA welding with a high-frequency device for arc start may cause electromagnetic noise problems for the computer equipment placed on the ISS (International Space Station). Therefore, in this report, welding experiments of space GHTA welding using aluminum alloy with a high-voltage DC device for arc start were carried out at the ISS orbital pressure, 10-5 Pa. It is clear from the experiments using a high-voltage DC device in a high-vacuum condition, that there is a shifting phenomenon in which the spark discharge shifts to either a glow discharge or an arc discharge when starting the arc. Welding projects in space need an arc discharge, so we investigated the effects of welding parameters on the arc formation ratio. As a result, space GHTA welding with a high-voltage DC device can be used for arc start when welding at the ISS orbital pressure.

Ultrasonic Welding of Graphite/Thermoplastic Composite

NASA Technical Reports Server (NTRS)

Hardy, S. S.; Page, D. B.

1982-01-01

Ultrasonic welding of graphite/thermoplastic composite materials eliminates need for fasteners (which require drilling or punching, add weight, and degrade stiffness) and can be totally automated in beam fabrication and assembly jigs. Feasibility of technique has been demonstrated in laboratory tests which show that neither angular orientation nor vacuum affect weld quality.

NASA welding assessment program

NASA Technical Reports Server (NTRS)

Patterson, R. E.

1985-01-01

A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

Portable electron beam weld chamber

NASA Technical Reports Server (NTRS)

Lewis, J. R.; Dimino, J. M.

1972-01-01

Development and characteristics of portable vacuum chamber for skate type electron beam welding are discussed. Construction and operational details of equipment are presented. Illustrations of equipment are provided.

Laser sealed vacuum insulation window

DOEpatents

Benson, David K.; Tracy, C. Edwin

1987-01-01

A laser sealed evacuated window panel is comprised of two glass panes held spaced apart in relation to each other by a plurality of spherical glass beads and glass welded around the edges to provide an evacuated space between the glass panes that is completely glass sealed from the exterior. The glass welded edge seal is obtained by welding the edges of the glass panes together with a laser beam while the glass panes and bead spacers are positioned in a vacuum furnace and heated to the annealing point of the glass to avoid stress fracture in the area of the glass weld. The laser welding in the furnace can be directed around the perimeter of the glass panel by a combination of rotating the glass panel and linearly translating or aiming the laser with a relay mirror.

Laser sealed vacuum insulating window

DOEpatents

Benson, D.K.; Tracy, C.E.

1985-08-19

A laser sealed evacuated window panel is comprised of two glass panes held spaced apart in relation to each other by a plurality of spherical glass beads and glass welded around the edges to provide an evacuated space between the glass panes that is completely glass sealed from the exterior. The glass welded edge seal is obtained by welding the edges of the glass panes together with a laser beam while the glass panes and bead spacers are positioned in a vacuum furnace and heated to the annealing point of the glass to avoid stress fracture in the area of the glass weld. The laser welding in the furnace can be directed around the perimeter of the galss panel by a combination of rotating the glass panel and linearly translating or aiming the laser with a relay mirror.

Optimization of a vacuum chamber for vibration measurements.

PubMed

Danyluk, Mike; Dhingra, Anoop

2011-10-01

A 200 °C high vacuum chamber has been built to improve vibration measurement sensitivity. The optimized design addresses two significant issues: (i) vibration measurements under high vacuum conditions and (ii) use of design optimization tools to reduce operating costs. A test rig consisting of a cylindrical vessel with one access port has been constructed with a welded-bellows assembly used to seal the vessel and enable vibration measurements in high vacuum that are comparable with measurements in air. The welded-bellows assembly provides a force transmissibility of 0.1 or better at 15 Hz excitation under high vacuum conditions. Numerical results based on design optimization of a larger diameter chamber are presented. The general constraints on the new design include material yield stress, chamber first natural frequency, vibration isolation performance, and forced convection heat transfer capabilities over the exterior of the vessel access ports. Operating costs of the new chamber are reduced by 50% compared to a preexisting chamber of similar size and function.

Welding and Joining of Titanium Aluminides

PubMed Central

Cao, Jian; Qi, Junlei; Song, Xiaoguo; Feng, Jicai

2014-01-01

Welding and joining of titanium aluminides is the key to making them more attractive in industrial fields. The purpose of this review is to provide a comprehensive overview of recent progress in welding and joining of titanium aluminides, as well as to introduce current research and application. The possible methods available for titanium aluminides involve brazing, diffusion bonding, fusion welding, friction welding and reactive joining. Of the numerous methods, solid-state diffusion bonding and vacuum brazing have been most heavily investigated for producing reliable joints. The current state of understanding and development of every welding and joining method for titanium aluminides is addressed respectively. The focus is on the fundamental understanding of microstructure characteristics and processing–microstructure–property relationships in the welding and joining of titanium aluminides to themselves and to other materials. PMID:28788113

Welding wire selection critical to jet engine repair work

NASA Astrophysics Data System (ADS)

1992-11-01

A review is provided of issues related to the selection of welding wire for aircraft gas-turbine engines emphasizing the importance of cleanliness in the welding wire product. A three-step metallurgical control process is described for the production of welding wire that is clean and suitable for turbine repair. The process is based on: (1) vacuum induction melting; (2) contamination-free processing of the wire; and (3) environmentally controlled packaging. Weld work on aerospace casting is shown to be useful and suitable for many alloy and superalloy materials with various filler materials.

Study on vacuum packaging reliability of micromachined quartz tuning fork gyroscopes

NASA Astrophysics Data System (ADS)

Fan, Maoyan; Zhang, Lifang

2017-09-01

Packaging technology of the micromachined quartz tuning fork gyroscopes by vacuum welding has been experimentally studied. The performance of quartz tuning fork is influenced by the encapsulation shell, encapsulation method and fixation of forks. Alloy solder thick film is widely used in the package to avoid the damage of the chip structure by the heat resistance and hot temperature, and this can improve the device performance and welding reliability. The results show that the bases and the lids plated with gold and nickel can significantly improve the airtightness and reliability of the vacuum package. Vacuum packaging is an effective method to reduce the vibration damping, improve the quality factor and further enhance the performance. The threshold can be improved nearly by 10 times.

Vacuum Plasma Spraying Replaces Electrodeposition

NASA Technical Reports Server (NTRS)

Holmes, Richard R.; Power, Chris; Burns, David H.; Daniel, Ron; Mckechnie, Timothy N.

1992-01-01

Vacuum plasma spraying used to fabricate large parts with complicated contours and inner structures, without uninspectable welds. Reduces time, and expense of fabrication. Wall of combustion chamber built up inside of outer nickel-alloy jacket by plasma spraying. Particles of metal sprayed partially melted in plasma gun and thrown at supersonic speed toward deposition surface. Vacuum plasma-spray produces stronger bond between the grooves and covering layer completing channels and wall of combustion chamber. In tests, bond withstood pressure of 20 kpsi, three times allowable limit by old method.

Compact vacuum insulation

DOEpatents

Benson, D.K.; Potter, T.F.

1993-01-05

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially point'' or line'' contacts with the metal wall sheets. In the case of monolithic spacers that form line'' contacts, two such spacers with the line contacts running perpendicular to each other form effectively point'' contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.

Compact vacuum insulation

DOEpatents

Benson, David K.; Potter, Thomas F.

1993-01-01

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially "point" or "line" contacts with the metal wall sheets. In the case of monolithic spacers that form "line" contacts, two such spacers with the line contacts running perpendicular to each other form effectively "point" contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.

Welding of HSLA-100 steel using ultra low carbon bainitic weld metal to eliminate preheating

DOE Office of Scientific and Technical Information (OSTI.GOV)

Devletian, J.H.; Singh, D.; Wood, W.E.

1996-12-31

Advanced high strength steels such as the Navy`s HSLA-100 and HSLA-80 contain sufficiently low carbon levels to be weldable without preheating. Unfortunately, commercial filler metals specifically designed to weld these steels without costly preheating have not yet been developed. The objective of this paper is to show that the Navy`s advanced steels can be welded by gas metal-arc (GMAW) and gas tungsten-arc welding (GTAW) without preheating by using filler metal compositions that produce weld metal with an ultra-low carbon bainitic (ULCB) microstructure. Filler metals were fabricated from vacuum induction melted (VIM) ingots containing ultra-low levels of C, O and N.more » HSLA-100 plate and plate from the VIM ingots were welded by both GMAW and GTAW with Ar-5% CO{sub 2} shielding gas using welding conditions to achieve cooling times from 800 to 500 C (t{sub 8-5}) from 35 to 14 sec. Weld metal tensile, hardness and CVN impact toughness testing as well as microstructural studies using transmission electron microscopy were conducted. The ULCB weld metal was relatively insensitive to cooling rate, resulting in good strength and toughness values over a wide range of t{sub 8-5} cooling times. Filler metal compositions which met the mechanical property requirements for HSLA-100, HSLA-80 and HSLA-65 weld metal were developed.« less

Technical specification for vacuum systems

DOE Office of Scientific and Technical Information (OSTI.GOV)

Khaw, J.

The vacuum systems at the Stanford Linear Accelerator Center (SLAC) are primarily of all-metal construction and operate at pressures from 10/sup -5/ to 10/sup -11/ Torr. The primary gas loads during operation result from thermal desorption and beam-induced desorption from the vacuum chamber walls. These desorption rates can be extremely high in the case of hydrocarbons and other contaminants. These specifications place a major emphasis on eliminating contamination sources. The specifications and procedures have been written to insure the cleanliness and vacuum integrity of all SLAC vacuum systems, and to assist personnel involved with SLAC vacuum systems in choosing andmore » designing components that are compatible with existing systems and meet the quality and reliability of SLAC vacuum standards. The specification includes requirements on design, procurement, fabrication, chemical cleaning, clean room practices, welding and brazing, helium leak testing, residual gas analyzer testing, bakeout, venting, and pumpdown. Also appended are specifications regarding acceptable vendors, isopropyl alcohol, bakeable valve cleaning procedure, mechanical engineering safety inspection, notes on synchrotron radiation, and specifications of numerous individual components. (LEW)« less

The use of ion beam cleaning to obtain high quality cold welds with minimal deformation

NASA Technical Reports Server (NTRS)

Sater, B. L.; Moore, T. J.

1978-01-01

A variation of cold welding is described which utilizes an ion beam to clean mating surfaces prior to joining in a vacuum environment. High quality solid state welds were produced with minimal deformation.

Compact vacuum insulation embodiments

DOEpatents

Benson, David K.; Potter, Thomas F.

1992-01-01

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially "point" or "line" contacts with the metal wall sheets. In the case of monolithic spacers that form "line" contacts, two such spacers with the line contacts running perpendicular to each other form effectively "point" contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included.

Microstructures and Mechanical Properties of Weld Metal and Heat-Affected Zone of Electron Beam-Welded Joints of HG785D Steel

NASA Astrophysics Data System (ADS)

Zhang, Qiang; Han, Jianmin; Tan, Caiwang; Yang, Zhiyong; Wang, Junqiang

2016-12-01

Vacuum electron beam welding (EBW) process was employed to butt weld 10-mm-thick HG785D high-strength steels. The penetration into the steel was adjusted by beam current. Microstructures at weld metal and heat-affected zone (HAZ) regions were comparatively observed. Mechanical properties of the EBWed joints including Vickers hardness, tensile and Charpy impact tests were evaluated. The results indicated that microstructures at the weld metal consisted of coarse lath martensite and a small amount of acicular martensite, while that in the HAZ was tempered sorbite and martensite. The grain size in the weld metal was found to be larger than that in the HAZ, and its proportion in weld metal was higher. The hardness in the weld metal was higher than the HAZ and base metal. The tensile strength and impact toughness in the HAZ was higher than that in the weld metal. All the behaviors were related to microstructure evolution caused by higher cooling rates and state of base metal. The fracture surfaces of tensile and impact tests on the optimized joint were characterized by uniform and ductile dimples. The results differed significantly from that obtained using arc welding process.

Compound Walls For Vacuum Chambers

NASA Technical Reports Server (NTRS)

Frazer, Robert E.

1988-01-01

Proposed compound-wall configuration enables construction of large high-vacuum chambers without having to use thick layers of expensive material to obtain necessary strength. Walls enclose chambers more than 1 m in diameter and several kilometers long. Compound wall made of strong outer layer of structural-steel culvert pipe welded to thin layer of high-quality, low-outgassing stainless steel.

Onorbit electron beam welding experiment definition

NASA Technical Reports Server (NTRS)

1989-01-01

The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

Tensile strength of simulated and welded butt joints in W-Cu composite sheet

NASA Technical Reports Server (NTRS)

Moore, Thomas J.; Watson, Gordon K.

1994-01-01

The weldability of W-Cu composite sheet was investigated using simulated and welded joints. The welded joints were produced in a vacuum hot press. Tensile test results showed that simulated joints can provide strength and failure mode data which can be used in joint design for actual weldments. Although all of the welded joints had flaws, a number of these joints were as strong as the W-Cu composite base material.

Compact vacuum insulation embodiments

DOEpatents

Benson, D.K.; Potter, T.F.

1992-04-28

An ultra-thin compact vacuum insulation panel is comprised of two hard, but bendable metal wall sheets closely spaced apart from each other and welded around the edges to enclose a vacuum chamber. Glass or ceramic spacers hold the wall sheets apart. The spacers can be discrete spherical beads or monolithic sheets of glass or ceramic webs with nodules protruding therefrom to form essentially point' or line' contacts with the metal wall sheets. In the case of monolithic spacers that form line' contacts, two such spacers with the line contacts running perpendicular to each other form effectively point' contacts at the intersections. Corrugations accommodate bending and expansion, tubular insulated pipes and conduits, and preferred applications are also included. 26 figs.

Electron Beam Welding: study of process capability and limitations towards development of nuclear components

NASA Astrophysics Data System (ADS)

Vadolia, Gautam R.; Premjit Singh, K.

2017-04-01

Electron Beam Welding (EBW) technology is an established and widely adopted technique in nuclear research and development area. Electron beam welding was thought of as a candidate process for ITER Vacuum Vessel Fabrication. Dhruva Reactor at BARC, Mumbai and Niobium superconducting accelerator cavity at BARC has adopted the EB welding technique as a fabrication route. Study of process capability and limitations based on available literature is consolidated in this short review paper.

The use of ion beam cleaning to obtain high quality cold welds with minimal deformation

NASA Technical Reports Server (NTRS)

Sater, B. L.; Moore, T. J.

1978-01-01

This paper describes a variation of cold welding which utilizes an ion beam to clean mating surfaces prior to joining in a vacuum environment. High quality solid state welds were produced with minimal deformation. Due to experimental fixture limitation in applying pressure work has been limited to a few low yield strength materials.

Small-scale explosive seam welding. [using ribbon explosive encased in lead sheath

NASA Technical Reports Server (NTRS)

Bement, L. J.

1972-01-01

A unique small scale explosive seam welding technique is reported that has successfully joined a variety of aluminum alloys and alloy combinations in thicknesses to 0.125 inch, as well as titanium in thicknesses to 0.056 inch. The explosively welded joints are less than one-half inch in width and apparently have no long length limitation. The ribbon explosive developed in this study contains very small quantities of explosive encased in a flexible thin lead sheath. The evaluation and demonstration of this welding technique was accomplished in three phases: evaluation and optimization of ten major explosive welding variables, the development of four weld joints, and an applicational analysis which included photomicrographs, pressure integrity tests, vacuum effects, and fabrication of some potentially useful structures in aluminum and titanium.

Experimental studies of diffusion welding of YBCO to copper using solder layers

NASA Astrophysics Data System (ADS)

Xie, Y.; Ouyang, Z.; Shi, L.; Kuang, Z.; Meng, M.

2017-02-01

The welding technology is of great importance in YBCO application. To make better joints, the diffusion welding of YBCO tape to copper has been carried out in a vacuum environment. In consideration of high welding temperature (above 200°C) could do damage to the material performance, a new kind of diffusion welding method with temperature below 200 °C has been developed recently. A new welding appliance which can offer pressure over 35Kg/mm2 and controlled temperature has been designed and built; several YBCO coated conductors joints soldered with different melting points of tins has been tested. The results showed that the diffusion can perfectly connect YBCO to copper as well as stainless steel and resistance of the joint was low, and the YBCO tape could bear 217°C for at least 15mins.

Simultaneous laser cutting and welding of metal foil to edge of a plate

DOEpatents

Pernicka, John C.; Benson, David K.; Tracy, C. Edwin

1996-01-01

A method of welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads.

Simultaneous laser cutting and welding of metal foil to edge of a plate

DOEpatents

Pernicka, J.C.; Benson, D.K.; Tracy, C.E.

1996-03-19

A method is described for welding an ultra-thin foil to the edge of a thicker sheet to form a vacuum insulation panel comprising the steps of providing an ultra-thin foil having a thickness less than 0.002, providing a top plate having an edge and a bottom plate having an edge, clamping the foil to the edge of the plate wherein the clamps act as heat sinks to distribute heat through the foil, providing a laser, moving the laser relative to the foil and the plate edges to form overlapping weld beads to weld the foil to the plate edges while simultaneously cutting the foil along the weld line formed by the overlapping beads. 7 figs.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in the Space Shuttle Bay at LEO for the International Space Welding Experiment

NASA Technical Reports Server (NTRS)

Fragomeni, James M.

1996-01-01

possible causes such as welder procedural error, externally applied impulsive forces(s), filler wire entrainment and snap-out, cutting expulsion, and puddle expulsion. Molten metal detachment from either the weld/cut substrate or weld wire could present harm to a astronaut in the space environment it the detachment was ti burn through the fabric of the astronaut Extravehicular Mobility Unit (EMC). In this paper an experimental test was performed in a 4 ft. x 4 ft. vacuum chamber at MSFC enabling protective garment to be exposed to the molten metal drop detachments to over 12 inches. The chamber was evacuated to vacuum levels of at least 1 x 10(exp -5) torr (50 micro-torr) during operation of the 1.0 kW Universal Hand Tool (UHT). The UHT was manually operated at the power mode appropriate for each material and thickness. The space suit protective welding garment, made of Teflon fabric (10 oz. per yard) with a plain weave, was placed on the floor of the vacuum chamber to catch the molten metal drop detachments. A pendulum release mechanism consisting of four hammers, each weighing approximately 3.65 lbs, was used to apply an impact forces to the weld sample/plate during both the electron beam welding and cutting exercises. Measurements were made of the horizontal fling distances of the detached molten metal drops. The volume of a molten metal drop can also be estimated from the size of the cut. Utilizing equations, calculations were made to determine chande in surafec area (Delat a(surface)) for 304 stainless steel for cutting based on measurements of metal drop sizes at the cut edges. For the cut sample of 304 stainless steel based on measurement of the drop size at the edge, Delta-a(surface) was determined to be 0.0054 2 in . Calculations have indicated only a small amount of energy is required to detach a liquid metal drop. For example, approximately only 0.000005 ft-lb of energy is necessary to detach a liquid metal steel drop based on the above theoretical analysis

Diffusion welding of MA 6000 and a conventional nickel-base superalloy

NASA Technical Reports Server (NTRS)

Moore, T. J.; Glasgow, T. K.

1985-01-01

A feasibility study of diffusion welding the oxide dispersion strengthened (ODS) alloy MA 6000 to itself and to conventional Ni-base superalloy Udimet 700 was conducted. Butt joints between MA 6000 pieces and lap joints between Udimet 700 and the ODS alloy were produced by hot pressing for 1.25 hr at temperatures ranging from 1000 to 1200 C (1832-2192 F) in vacuum. Following pressing, all weldments were heat treated and machined into mechanical property test specimens. While three different combinations of recrystallized and unrecrystallized MA 6000 butt joints were produced, the unrecrystallized to unrecrystallized joint was most successful as determined by mechanical properties and microstructural examination. Failure to weld the recrystallized material probably related to a lack of adequate deformation at the weld interface. While recrystallized MA 6000 could be diffusion welded to Udimet 700 in places, complete welding over the entire lap joint was not achieved, again due to the lack of sufficient deformation at the faying surfaces. Several methods are proposed to promote the intimate contact necessary for diffusion welding MA 6000 to itself and to superalloys.

BAKABLE ULTRA-HIGH VACUUM VALVE

DOEpatents

Mark, J.T.; Gantz, I.H.

1962-07-10

S>This patent relates to a valve useful in applications involving successively closing and opening a communication between a chamber evacuated to an ultra-high vacuum condition of the order of 10/sup -10/ millimeters of mercury and another chamber or the ambient. The valve is capable of withstanding extended baking at 450 deg C and repeated opening and closing without repiacement of the valve seat (approximately 200 cycle limit). The seal is formed by mutual interdiffusion weld, coerced by a pneumatic actuator. (AEC)

The thin-wall tube drift chamber operating in vacuum (prototype)

NASA Astrophysics Data System (ADS)

Alexeev, G. D.; Glonti, L. N.; Kekelidze, V. D.; Malyshev, V. L.; Piskun, A. A.; Potrbenikov, Yu. K.; Rodionov, V. K.; Samsonov, V. A.; Tokmenin, V. V.; Shkarovskiy, S. N.

2013-08-01

The goal of this work was to design drift tubes and a chamber operating in vacuum, and to develop technologies for tubes independent assembly and mounting in the chamber. These design and technology were tested on the prototype. The main features of the chamber are the following: the drift tubes are made of flexible mylar film (wall thickness 36 μm, diameter 9.80 mm, length 2160 mm) using ultrasonic welding along the generatrix; the welding device and methods were developed at JINR. Drift tubes with end plugs, anode wires and spacers were completely assembled outside the chamber. "Self-centering" spacers and bushes were used for precise setting of the anode wires and tubes. The assembled tubes were sealed with O-rings in their seats in the chamber which simplified the chamber assembling. Moreover the tube assembly and the chamber manufacture can be performed independently and in parallel; this sufficiently reduces the total time of chamber manufacture and assembling, its cost and allows tubes to be tested outside the chamber. The technology of independent tube assembling is suitable for a chamber of any shape but a round chamber is preferable for operation in vacuum. Single channel amplifier-discriminator boards which are more stable against cross talks were used for testing the tubes. Independently assembled tubes were mounted into the chamber prototype and its performance characteristic measured under the vacuum conditions. The results showed that both the structure and the tubes themselves normally operate. They are suitable for making a full-scale drift chamber for vacuum.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of

Vacuum vapor deposition

NASA Technical Reports Server (NTRS)

Poorman, Richard M. (Inventor); Weeks, Jack L. (Inventor)

1995-01-01

A method and apparatus is described for vapor deposition of a thin metallic film utilizing an ionized gas arc directed onto a source material spaced from a substrate to be coated in a substantial vacuum while providing a pressure differential between the source and the substrate so that, as a portion of the source is vaporized, the vapors are carried to the substrate. The apparatus includes a modified tungsten arc welding torch having a hollow electrode through which a gas, preferably inert, flows and an arc is struck between the electrode and the source. The torch, source, and substrate are confined within a chamber within which a vacuum is drawn. When the arc is struck, a portion of the source is vaporized and the vapors flow rapidly toward the substrate. A reflecting shield is positioned about the torch above the electrode and the source to ensure that the arc is struck between the electrode and the source at startup. The electrode and the source may be confined within a vapor guide housing having a duct opening toward the substrate for directing the vapors onto the substrate.

A review of the use of Al-alloy vacuum components for operation at 10-13 Torr

NASA Astrophysics Data System (ADS)

Ishimaru, Hajime

1990-02-01

An extremely high vacuum (XHV) chamber was fabricated and tested. The vacuum chamber was made of special surface finished (EX-process) aluminum alloy in oxygen and argon atmosphere. The chamber was assembled using TIG welding in an argon atmosphere and by electron beam welding. The system was evacuated with a turbo-backed 300 l/s turbomolecular pump separated from the main chamber using a right angle valve. The liquid nitrogen shroud is installed inside the main vacuum chamber. The XHV is maintained by two 300 l/s sputter ion pumps and a titanium sublimation pump with a liquid nitrogen shroud. These pumps are also made of aluminum alloys. An ultimate pressure of 3×10-13 Torr was measured with a point collector gauge with a spherical anode mounted on an Al-flange. Residual gas analysis in the order 10-13 Torr was performed by a newly developed Q-mass filter. To suppress outgassing from the quadrupole electrode, the ion source is mounted on an Al-flange separated from the quadrupole electrode.

A drift chamber with a new type of straws for operation in vacuum

NASA Astrophysics Data System (ADS)

Azorskiy, N.; Glonti, L.; Gusakov, Yu.; Elsha, V.; Enik, T.; Kakurin, S.; Kekelidze, V.; Kislov, E.; Kolesnikov, A.; Madigozhin, D.; Movchan, S.; Polenkevich, I.; Potrebenikov, Yu.; Samsonov, V.; Shkarovskiy, S.; Sotnikov, S.; Zinchenko, A.; Danielsson, H.; Bendotti, J.; Degrange, J.; Dixon, N.; Lichard, P.; Morant, J.; Palladino, V.; Gomez, F. Perez; Ruggiero, G.; Vergain, M.

2016-07-01

A 2150×2150 mm2 registration area drift chamber capable of working in vacuum is presented. Thin-wall tubes (straws) of a new type are used in the chamber. A large share of these 9.80 mm diameter drift tubes are made in Dubna from metalized 36 μm Mylar film welded along the generatrix using an ultrasonic welding machine created at JINR. The main features of the chamber and some characteristics of the drift tubes are described. Four such chambers with the X, Y, U, V coordinates each, containing 7168 straws in total, are designed and produced at JINR and CERN. They are installed in the vacuum volume of the NA62 setup in order to study the ultra-rare decay K+ →π+ vv bar and to search for and study rare meson decays. In autumn 2014 the chambers were used for the first time for the data taking in the experimental run of the NA62 at CERN's SPS.

An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space

NASA Technical Reports Server (NTRS)

Fragomeni, James M.; Nunes, Arthur C., Jr.

1998-01-01

tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of

SRF test facility for the superconducting LINAC ``RAON'' — RRR property and e-beam welding

NASA Astrophysics Data System (ADS)

Jung, Yoochul; Hyun, Myungook; Joo, Jongdae; Joung, Mijoung

2015-02-01

Equipment, such as a vacuum furnace, high pressure rinse (HPR), eddy current test (ECT) and buffered chemical polishing (BCP), are installed in the superconducting radio frequency (SRF) test facility. Three different sizes of cryostats (diameters of 600 mm for a quarter wave resonator (QWR), 900 mm for a half wave resonator (HWR), and 1200 mm for single spoke resonator 1&2 (SSR 1&2)) for vertical RF tests are installed for testing cavities. We confirmed that as-received niobium sheets (ASTM B393, RRR300) good electrical properties because they showed average residual resistance ratio (RRR) values higher than 300. However, serious RRR degradation occurred after joining two pieces of Nb by e-beam welding because the average RRR values of the samples were ˜179, which was only ˜60% of as-received RRR value. From various e-beam welding experiments in which the welding current and a speed at a fixed welding voltage were changed, we confirmed that good welding results were obtained at a 53 mA welding current and a 20-mm/s welding speed at a fixed welding voltage of 150 kV.

Soldadura (Welding). Spanish Translations for Welding.

ERIC Educational Resources Information Center

Hohhertz, Durwin

Thirty transparency masters with Spanish subtitles for key words are provided for a welding/general mechanical repair course. The transparency masters are on such topics as oxyacetylene welding; oxyacetylene welding equipment; welding safety; different types of welds; braze welding; cutting torches; cutting with a torch; protective equipment; arc…

Spin-rolling, welding, and heat treatment of aluminium 2219 for Ariane 5 GAM high pressure vessel liners

NASA Astrophysics Data System (ADS)

Radtke, W.

1992-10-01

Cylindrical liners made of Al 2219 may be spinrolled if both recrystallization and metastable precipitates can be avoided during forging or preparatory heat treatment. So welding is to be limited to circumferential joints. Pore-free welds are attainable immediately after hydroxide layer removal by diamond cutting without grease application. The EB vacuum is favorable to porosity suppression. A complete heat treatment of the liner incorporating solutionizing, water quenching and ageing leads to 100 percent weld efficiency. Pressure stabilization avoids buckling. Subsequent carbon fiber winding, curing and plastic prestressing of the liner results in an efficient high pressure vessel for hydrogen service.

Modern fiber laser beam welding of the newly-designed precipitation-strengthened nickel-base superalloys

NASA Astrophysics Data System (ADS)

Naffakh Moosavy, Homam; Aboutalebi, Mohammad-Reza; Seyedein, Seyed Hossein; Goodarzi, Massoud; Khodabakhshi, Meisam; Mapelli, Carlo; Barella, Silvia

2014-04-01

In the present research, the modern fiber laser beam welding of newly-designed precipitation-strengthened nickel-base superalloys using various welding parameters in constant heat input has been investigated. Five nickel-base superalloys with various Ti and Nb contents were designed and produced by Vacuum Induction Melting furnace. The fiber laser beam welding operations were performed in constant heat input (100 J mm-2) and different welding powers (400 and 1000 W) and velocities (40 and 100 mm s-1) using 6-axis anthropomorphic robot. The macro- and micro-structural features, weld defects, chemical composition and mechanical property of 3.2 mm weldments were assessed utilizing optical and scanning electron microscopes equipped with EDS analysis and microhardness tester. The results showed that welding with higher powers can create higher penetration-to-width ratios. The porosity formation was increased when the welding powers and velocities were increased. None of the welds displayed hot solidification and liquation cracks in 400 and 1000 W welding powers, but liquation phenomenon was observed in all the heat-affected zones. With increasing the Nb content of the superalloys the liquation length was increased. The changing of the welding power and velocity did not alter the hardness property of the welds. The hardness of welds decreased when the Ti content declined in the composition of superalloys. Finally, the 400 and 1000 W fiber laser powers with velocity of 40 and 100 m ms-1 have been offered for hot crack-free welding of the thin sheet of newly-designed precipitation-strengthened nickel-base superalloys.

Construction of vacuum system for Tristan accumulation ring

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ishimaru, H.; Horikoshi, G.; Kobayashi, M.

1983-08-01

An all aluminum-alloy vacuum system for the TRISTAN accumulation ring is now under construction. Aluminum and aluminum alloys are preferred materials for ultrahigh vacuum systems of large electron storage rings because of their good thermal conductivity, extremely low outgassing rate, and low residual radioactivity. Vacuum beam chambers for the dipole and quadrupole magnets are extruded using porthole dies. The aluminum alloy 6063-T6 provides superior performance in extrusion. For ultrahigh vacuum performance, a special extrusion technique is applied which, along with the outgassing procedure used, is described in detail. Aluminum alloy 3004 seamless elliptical bellows are inserted between the dipole andmore » quadrupole magnet chambers. These bellows are produced by the hydraulic forming of a seamless tube. The seamless bellows and the beam chambers are joined by fully automatic welding. The ceramic chambers for the kicker magnets, the fast bump magnets, and the slow beam intensity monitor are inserted in the aluminum alloy beam chambers. The ceramic chamber (98% alumina) and elliptical bellows are brazed with brazing sheets (4003-3003-4003) in a vacuum furnace. The brazing technique is described. The inner surface of the ceramic chamber is coated with a TiMo alloy by vacuum evaporation to permit a smooth flow of the RF wall current. Other suitable aluminum alloy components, including fittings, feedthroughs, gauges, optical windows, sputter ion pumps, turbomolecular pumps, and valves have been developed; their fabrication is described.« less

Toroid Joining Gun. [thermoplastic welding system using induction heating

NASA Technical Reports Server (NTRS)

Buckley, J. D.; Fox, R. L.; Swaim, R J.

1985-01-01

The Toroid Joining Gun is a low cost, self-contained, portable low powered (100-400 watts) thermoplastic welding system developed at Langley Research Center for joining plastic and composite parts using an induction heating technique. The device developed for use in the fabrication of large space sructures (LSST Program) can be used in any atmosphere or in a vacuum. Components can be joined in situ, whether on earth or on a space platform. The expanded application of this welding gun is in the joining of thermoplastic composites, thermosetting composites, metals, and combinations of these materials. Its low-power requirements, light weight, rapid response, low cost, portability, and effective joining make it a candidate for solving many varied and unique bonding tasks.

Development and fabrication of a diffusion welded Columbium alloy heat exchanger. [for space power generation

NASA Technical Reports Server (NTRS)

Zimmerman, W. F.; Duderstadt, E. C.; Wein, D.; Titran, R. H.

1978-01-01

A Mini Brayton space power generation system required the development of a Columbium alloy heat exchanger to transfer heat from a radioisotope heat source to a He/Xe working fluid. A light-weight design featured the simultaneous diffusion welding of 148 longitudinal fins in an annular heat exchanger about 9-1/2 in. in diameter, 13-1/2 in. in length and 1/4 in. in radial thickness. To complete the heat exchanger, additional gas ducting elements and attachment supports were added by GTA welding in a vacuum-purged inert atmosphere welding chamber. The development required the modification of an existing large size hot isostatic press to achieve HIP capabilities of 2800 F and 10,000 psi for at least 3 hr. Excellent diffusion welds were achieved in a high-quality component which met all system requirements.

A Plasma Window for Transmission of Radiation and Particle Beams from Vacuum to Atmosphere for Various Applications

NASA Astrophysics Data System (ADS)

Hershcovitch, Ady

1997-11-01

Many industrial and scientific processes like electron beam melting and welding, material modification by ion implantation, dry etching, and micro-fabrication, as well as generation of synchrotron radiation are performed almost exclusively in vacuum nowadays, since the electron and ion guns and their extractors must be kept at a reasonably high vacuum. Consequently, there are numerous drawbacks, among which are low production rates due to required pumping time, limits the vacuum volume sets on the size of target objects. In a small number of applications like non-vacuum electron beam welding, and various processes involving UV and x-ray radiation, thin vacuum walls or long stages of differential pumping are used. But, the resultant degradations of particle and radiation beams severely limit those applications. A novel apparatus, which utilized a short plasma arc, was successfully used to maintain a pressure of 7.6 x exp(-6) Torr in a vacuum chamber with a 2.36mm aperture to atmosphere, i.e., a plasma was successfully used to "plug" a hole to atmosphere while maintaining a reasonably high vacuum in the chamber. Successful transmission of charged particle beams from a vacuum through the plasma to atmosphere was accomplished. More details can be found in A. Hershcovitch, J. Appl. Physics 78, p. 5283 (1995). In addition to sustaining a vacuum atmosphere interface, the plasma has very strong lensing effect on charged particles. The plasma current generates an azimuthal magnetic field which exerts a radial Lorentz on charged particles moving parallel to the current channel. With proper orientation of the current direction, the Lorentz force is radially inward. This feature can be used to focus in beams to a very small spot size, and to overcome beam dispersion due to scattering by atmospheric atoms and molecules. Relatively hot plasma at the atmosphere boundary rarefies the atmospheric gases to further enhance particle beam propagation to the materials to target. Recent

Progress and achievements of R&D activities for the ITER vacuum vessel

NASA Astrophysics Data System (ADS)

Nakahira, M.; Takahashi, H.; Koizumi, K.; Onozuka, M.; Ioki, K.

2001-04-01

The Full Scale Sector Model Project, which was initiated in 1995 as one of the Seven Large Projects for ITER R&D, has been continued with the joint effort of the ITER Joint Central Team and the Japanese, Russian Federation and United States Home Teams. The fabrication of a full scale 18° toroidal sector, which is composed of two 9° sectors spliced at the port centre, was successfully completed in September 1997 with a dimensional accuracy of +/-3 mm for the total height and total width. Both sectors were shipped to the test site at the Japan Atomic Energy Research Institute and the integration test of the sectors was begun in October 1997. The integration test involves the adjustment of field joints, automatic narrow gap tungsten inert gas welding of field joints with splice plates and inspection of the joints by ultrasonic testing, as required for the initial assembly of the ITER vacuum vessel. This first demonstration of field joint welding and the performance test of the mechanical characteristics were completed in May 1998, and all the results obtained have satisfied the ITER design. In addition to these tests, integration with the midplane port extension fabricated by the Russian Home Team by using a fully remotized welding and cutting system developed by the US Home Team was completed in March 2000. The article describes the progress, achievements and latest status of the R&D activities for the ITER vacuum vessel.

Friction Stir Weld System for Welding and Weld Repair

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor); Romine, Peter L. (Inventor); Oelgoetz, Peter A. (Inventor)

2001-01-01

A friction stir weld system for welding and weld repair has a base foundation unit connected to a hydraulically controlled elevation platform and a hydraulically adjustable pin tool. The base foundation unit may be fixably connected to a horizontal surface or may be connected to a mobile support in order to provide mobility to the friction stir welding system. The elevation platform may be utilized to raise and lower the adjustable pin tool about a particular axis. Additional components which may be necessary for the friction stir welding process include back plate tooling, fixturing and/or a roller mechanism.

Feasibility of Underwater Friction Stir Welding of Hardenable Alloy Steel

DTIC Science & Technology

2010-12-01

Base Material CNC – Computer Numerical Controlled EDM – Electrical Discharge Machining FSP – Friction Stir Processing FSW – Friction Stir Welding...Hydrogen content was determined through vacuum hot extraction according to ASTM E 146-83. All other components were analyzed by direct current plasma ...emission spectroscopy according to ASTM E 1097-07. C. MICROSTRUCTURE ANALYSIS 1. Specimen Preparation A Charmilles Andrew EF630 CNC Wire EDM

Weld pool oscillation during pulsed GTA welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Aendenroomer, A.J.R.; Ouden, G. den

1996-12-31

This paper deals with weld pool oscillation during pulsed GTA welding and with the possibility to use this oscillation for in-process control of weld penetration. Welding experiments were carried out under different welding conditions. During welding the weld pool was triggered into oscillation by the normal welding pulses or by extra current pulses. The oscillation frequency was measured both during the pulse time and during the base time by analyzing the arc voltage variation using a Fast Fourier Transformation program. Optimal results are obtained when full penetration occurs during the pulse time and partial penetration during the base time. Undermore » these conditions elliptical overlapping spot welds are formed. In the case of full penetration the weld pool oscillates in a low frequency mode (membrane oscillation), whereas in the case of partial penetration the weld pool oscillates in a high frequency mode (surface oscillation). Deviation from the optimal welding conditions occurs when high frequency oscillation is observed during both pulse time and base time (underpenetration) or when low frequency oscillation is observed during both pulse time and base time (overpenetration). In line with these results a penetration sensing system with feedback control was designed, based on the criterion that optimal weld penetration is achieved when two peaks are observed in the frequency distribution. The feasibility of this sensing system for orbital tube welding was confirmed by the results of experiments carried out under various welding conditions.« less

Apparatus and Method for Cold Welding Thin Wafers to Hard Substrates

NASA Technical Reports Server (NTRS)

Oeftering, Richard C. (Inventor); Smith, Floyd A. (Inventor)

1996-01-01

An apparatus for coating and bonding parts in a vacuum includes a floating mount assembly holding one part and applying a bonding load to the parts. A pivoting mount assembly holds one part and is pivoted between a coating position and a bonding position. At least one coating source is provided for depositing a thin film of a metal onto a surface of each of the parts to improve the cold weld between the two parts. A restraining lever controls the application of the bonding load to the parts. The coating and bonding process occurs in a vacuum chamber with a single set-up.

Evaluation of the Low Heat Input Process for Weld Repair of Nickel-Base Superalloys

NASA Astrophysics Data System (ADS)

Durocher, J.; Richards, N. L.

2011-10-01

The repair of turbine blades and vanes commonly involves gas tungsten arc welding or an equivalent process, but unfortunately these components are often susceptible to heat-affected zone (HAZ) cracking during the weld repair process. This is a major problem especially in cast alloys due to their coarse-grain size and where the (Al + Ti) contents is in excess of 3-4%; vacuum brazing is also used but mainly on low stress non-rotating components such as vanes. Micro-welding has the potential to deposit small amounts of filler at low heat input levels with minimum HAZ and thus is an attractive process for depositing a quality weld. As with conventional fusion processes, the filler alloy is deposited by the generation of a low power arc between a consumable electrode and the substrate. The low heat input of this process offers unique advantages over more common welding processes such as gas tungsten arc, plasma arc, laser, and electron beam welding. In this study, the low heat input characteristic of micro-welding has been used to simulate weld repair using Inconel (IN) (Inconel and IN are trademarks of INCO Alloys International) 625, Rene (Rene is a trademark of General Electric Company) 41, Nimonic (Nimonic is a trademark of INCO Alloys International) 105 and Inconel 738LC filler alloys, to a cast Inconel 738LC substrate. The effect of micro-welding process parameters on the deposition rate, coating quality, and substrate has been investigated.

Internal friction and velocity measurements. [vacuum effects on lunar basalt resonance

NASA Technical Reports Server (NTRS)

Tittmann, B. R.; Ahlberg, L.; Curnow, J.

1976-01-01

The Q of a lunar basalt sample was measured under varying vacuum conditions, and it was found that even at pressures as low as 10 to the -7th to 10 to the -10th torr, substantial increases in Q with decreasing pressure are observed, while the resonant frequency increases only slightly. This suggests that only small amounts of volatiles are sufficient to increase the internal friction (lower the Q) dramatically. The technique of vibrating encapsulated samples in the torsional mode was used to measure Q of terrestrial rocks as a function of hydrostatic pressure under lunar vacuum conditions. Young's modulus measurements in the temperature range 25-600 C under a variety of conditions including high vacuum show no evidence of any irreversibility upon temperature cycling and no indication that the high Q-values obtained are associated with any permanent structure changes such as the formation of lossless 'welded' contacts.

Welding.

ERIC Educational Resources Information Center

South Carolina State Dept. of Education, Columbia. Office of Vocational Education.

This curriculum guide is designed for use by South Carolina vocational education teachers as a continuing set of lesson plans for a two-year course on welding. Covered in the individual sections of the guide are the following topics: an orientation to welding, oxyacetylene welding, advanced oxyacetylene welding, shielded metal arc welding, TIG…

Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hovanski, Yuri; Carsley, John; Carlson, Blair

2014-01-15

A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

Characterization of welded HP 9-4-30 steel for the advanced solid rocket motor

NASA Technical Reports Server (NTRS)

Watt, George William

1990-01-01

Solid rocket motor case materials must be high-strength, high-toughness, weldable alloys. The Advanced Solid Rocket Motor (ASRM) cases currently being developed will be made from a 9Ni-4Co quench and temper steel called HP 9-4-30. These ultra high-strength steels must be carefully processed to give a very clean material and a fine grained microstructure, which insures excellent ductility and toughness. The HP 9-4-30 steels are vacuum arc remelted and carbon deoxidized to give the cleanliness required. The ASRM case material will be formed into rings and then welded together to form the case segments. Welding is the desired joining technique because it results in a lower weight than other joining techniques. The mechanical and corrosion properties of the weld region material were fully studied.

Plasma arc welding weld imaging

NASA Technical Reports Server (NTRS)

Rybicki, Daniel J. (Inventor); Mcgee, William F. (Inventor)

1994-01-01

A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

Graphite composite truss welding and cap section forming subsystems. Volume 1: Executive summary. [large space structures

NASA Technical Reports Server (NTRS)

1980-01-01

A rolltrusion process was developed for forming of a hybrid, single-ply woven graphite and glass fiber cloth, impregnated with a polysulfone resin and coated with TI02 pigmented P-1700 resin into strips for the on-orbit fabrication of triangular truss segments. Ultrasonic welding in vacuum showed no identifiable effects on weld strength or resin flow characteristics. An existing bench model cap roll forming machine was modified and used to roll form caps for the prototype test truss and for column test specimens in order to test local buckling and torsional instability characteristics.

Modeling of the Weld Shape Development During the Autogenous Welding Process by Coupling Welding Arc with Weld Pool

NASA Astrophysics Data System (ADS)

Dong, Wenchao; Lu, Shanping; Li, Dianzhong; Li, Yiyi

2010-10-01

A numerical model of the welding arc is coupled to a model for the heat transfer and fluid flow in the weld pool of a SUS304 stainless steel during a moving GTA welding process. The described model avoids the use of the assumption of the empirical Gaussian boundary conditions, and at the same time, provides reliable boundary conditions to analyze the weld pool. Based on the two-dimensional axisymmetric numerical modeling of the argon arc, the heat flux to workpiece, the input current density, and the plasma drag stress are obtained. The arc temperature contours, the distributions of heat flux, and current density at the anode are in fair agreement with the reported experimental results. Numerical simulation and experimental studies to the weld pool development are carried out for a moving GTA welding on SUS304 stainless steel with different oxygen content from 30 to 220 ppm. The calculated result show that the oxygen can change the Marangoni convection from outward to inward direction on the liquid pool surface and make the wide shallow weld shape become narrow deep one. The calculated result for the weld shape and weld D/W ratio agrees well with the experimental one.

High energy density capacitors for vacuum operation with a pulsed plasma load

NASA Technical Reports Server (NTRS)

Guman, W. J.

1976-01-01

Results of the effort of designing, fabricating, and testing of a 40 joules/lb (88.2 joules/Kg) high voltage energy storage capacitor suitable for operating a pulsed plasma thruster in a vacuum environment for millions of pulses are presented. Using vacuum brazing and heli-arc welding techniques followed by vacuum and high pressure helium leak tests it was possible to produce a hermetically sealed relatively light weight enclosure for the dielectric system. An energy density of 40 joules/lb was realized with a KF-polyvinylidene fluoride dielectric system. One capacitor was D.C. life tested at 4 KV (107.8 joules/lb) for 2,000 hours before it failed. Another exceeded 2,670 hours without failure at 38.3 joules/lb. Pulse life testing in a vacuum exceeded 300,000 discharges with testing still in progress. The D.C. life test data shows a small decrease in capacitance and an increase in dissipation factor with time. Heat transfer from the load to the capacitor must also be considered besides the self-heat generated by the capacitor.

Investigation on mechanical properties of welded material under different types of welding filler (shielded metal arc welding)

NASA Astrophysics Data System (ADS)

Tahir, Abdullah Mohd; Lair, Noor Ajian Mohd; Wei, Foo Jun

2018-05-01

The Shielded Metal Arc Welding (SMAW) is (or the Stick welding) defined as a welding process, which melts and joins metals with an arc between a welding filler (electrode rod) and the workpieces. The main objective was to study the mechanical properties of welded metal under different types of welding fillers and current for SMAW. This project utilized the Design of Experiment (DOE) by adopting the Full Factorial Design. The independent variables were the types of welding filler and welding current, whereas the other welding parameters were fixed at the optimum value. The levels for types of welding filler were by the models of welding filler (E6013, E7016 and E7018) used and the levels for welding current were 80A and 90A. The responses were the mechanical properties of welded material, which include tensile strength and hardness. The experiment was analyzed using the two way ANOVA. The results prove that there are significant effects of welding filler types and current levels on the tensile strength and hardness of the welded metal. At the same time, the ANOVA results and interaction plot indicate that there are significant interactions between the welding filler types and the welding current on both the hardness and tensile strength of the welded metals, which has never been reported before. This project found that when the amount of heat input with increase, the mechanical properties such as tensile strength and hardness decrease. The optimum tensile strength for welded metal is produced by the welding filler E7016 and the optimum of hardness of welded metal is produced by the welding filler E7018 at welding current of 80A.

A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

NASA Technical Reports Server (NTRS)

Tamir, David

1992-01-01

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

NASA Technical Reports Server (NTRS)

Bjorkman, Gerry; Cantrell, Mark; Carter, Robert

2003-01-01

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading

Weld pool oscillation during GTA welding of mild steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Xiao, Y.H.; Ouden, G. den

1993-08-01

In this paper the results are reported of a study dealing with the oscillation behavior of weld pools in the case of GTA bead-on-plate welding of mild steel, Fe 360. During welding, the weld pool was brought into oscillation by applying short current pulses, and the oscillation frequency and amplitude were measured by monitoring the arc voltage. It was found that the oscillation of the partially penetrated weld pool is dominated by one of two different oscillation modes (Mode 1 and Mode 2) depending on the welding conditions, whereas the oscillation of the fully penetrated weld pool is characterized bymore » a third oscillation mode (Mode 3). It is possible to maintain partially penetrated weld pool oscillation in Mode 1 by choosing appropriate welding conditions. Under these conditions, an abrupt decrease in oscillation frequency occurs when the weld pool transfers from partial penetration to full penetration. Thus, weld penetration can be in-process controlled by monitoring the oscillation frequency during welding.« less

Manufacturing and assembly of IWS support rib and lower bracket for ITER vacuum vessel

NASA Astrophysics Data System (ADS)

Laad, R.; Sarvaiya, Y.; Pathak, H. A.; Raval, J. R.; Choi, C. H.

2017-04-01

ITER Vacuum Vessel (VV) is made of double walls connected by ribs structure and flexible housings. Space between these walls is filled up with In Wall Shielding (IWS) blocks to (1) shield neutrons streaming out of plasma and (2) reduce toroidal magnetic field ripple. These blocks will be connected to the VV through a supporting structure of Support Rib (SR) and Lower Bracket (LB) assembly. SR and LB are two independent components manufactured from SS 316L(N)-IG, Total 1584 support ribs and 3168 lower bracket of different sizes and shapes will be manufactured for the IWS. Two lower brackets will be welded with one support rib to make an assembly. The welding between SR and LB is a full penetration welding. Total 1584 assemblies of different sizes and shapes will be manufactured. Sufficient experience gained from manufacturing and testing of mock ups, final manufacturing of IWS support rib and lower bracket has been started at the site of IWS manufacturer M/s. Avasarala Technologies Limited (ATL). This paper will describe, optimization of water jet cutting speed on IWS material, selection criteria for K type weld joint, unique features of fixture of assembly, manufacturing of Mock ups, and welding processes with NDTs.

High Strain Rate Testing of Welded DOP-26 Iridium

DOE Office of Scientific and Technical Information (OSTI.GOV)

Schneibel, J. H.; Miller, R. G.; Carmichael, C. A.

The iridium alloy DOP-26 is used to produce Clad Vent Set cups that protect the radioactive fuel in radioisotope thermoelectric generators (RTGs) which provide electric power for spacecraft and rovers. In a previous study, the tensile properties of DOP-26 were measured over a wide range of strain rates and temperatures and reported in ORNL/TM-2007/81. While that study established the properties of the base material, the fabrication of the heat sources requires welding, and the mechanical properties of welded DOP-26 have not been extensively characterized in the past. Therefore, this study was undertaken to determine the mechanical properties of DOP-26 specimensmore » containing a transverse weld in the center of their gage sections. Tensile tests were performed at room temperature, 750, 900, and 1090°C and engineering strain rates of 1×10 -3 and 10 s -1. Room temperature testing was performed in air, while testing at elevated temperatures was performed in a vacuum better than 1×10 -4 Torr. The welded specimens had a significantly higher yield stress, by up to a factor of ~2, than the non-welded base material. The yield stress did not depend on the strain rate except at 1090°C, where it was slightly higher for the faster strain rate. The ultimate tensile stress, on the other hand, was significantly higher for the faster strain rate at temperatures of 750°C and above. At 750°C and above, the specimens deformed at 1×10 -3 s -1 showed pronounced necking resulting sometimes in perfect chisel-edge fracture. The specimens deformed at 10 s -1 exhibited this fracture behavior only at the highest test temperature, 1090°C. Fracture occurred usually in the fusion zone of the weld and was, in most cases, primarily intergranular.« less

Adaptive weld control for high-integrity welding applications

NASA Technical Reports Server (NTRS)

Powell, Bradley W.

1993-01-01

An advanced adaptive control weld system for high-integrity welding applications is presented. The system consists of a state-of-the-art weld control subsystem, motion control subsystem, and sensor subsystem which closes the loop on the process. The adaptive control subsystem (ACS), which is required to totally close the loop on weld process control, consists of a multiprocessor system, data acquisition hardware, and three welding sensors which provide measurements from all areas around the torch in real time. The ACS acquires all 'measurables' and feeds offset trims back into the weld control and motion control subsystems to modify the 'controllables' in order to maintain a previously defined weld quality.

Interdiffusion of Polycarbonate in Fused Deposition Modeling Welds

NASA Astrophysics Data System (ADS)

Seppala, Jonathan; Forster, Aaron; Satija, Sushil; Jones, Ronald; Migler, Kalman

2015-03-01

Fused deposition modeling (FDM), a now common and inexpensive additive manufacturing method, produces 3D objects by extruding molten polymer layer-by-layer. Compared to traditional polymer processing methods (injection, vacuum, and blow molding), FDM parts have inferior mechanical properties, surface finish, and dimensional stability. From a polymer processing point of view the polymer-polymer weld between each layer limits the mechanical strength of the final part. Unlike traditional processing methods, where the polymer is uniformly melted and entangled, FDM welds are typically weaker due to the short time available for polymer interdiffusion and entanglement. To emulate the FDM process thin film bilayers of polycarbonate/d-polycarbonate were annealed using scaled times and temperatures accessible in FDM. Shift factors from Time-Temperature Superposition, measured by small amplitude oscillatory shear, were used to calculate reasonable annealing times (min) at temperatures below the actual extrusion temperature. The extent of interdiffusion was then measured using neutron reflectivity. Analogous specimens were prepared to characterize the mechanical properties. FDM build parameters were then related to interdiffusion between welded layers and mechanical properties. Understating the relationship between build parameters, interdiffusion, and mechanical strength will allow FDM users to print stronger parts in an intelligent manner rather than using trial-and-error and build parameter lock-in.

Weld Nugget Temperature Control in Thermal Stir Welding

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey (Inventor)

2014-01-01

A control system for a thermal stir welding system is provided. The control system includes a sensor and a controller. The sensor is coupled to the welding system's containment plate assembly and generates signals indicative of temperature of a region adjacent and parallel to the welding system's stir rod. The controller is coupled to the sensor and generates at least one control signal using the sensor signals indicative of temperature. The controller is also coupled to the welding system such that at least one of rotational speed of the stir rod, heat supplied by the welding system's induction heater, and feed speed of the welding system's weld material feeder are controlled based on the control signal(s).

Study of weld offset in longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. S.; Brunair, R. M.

1992-01-01

Welded joints are an essential part of rocket engine structures such as the Space Shuttle Main Engine (SSME) turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet X-rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered in this report. Using the FEM and beamlike plate approximations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thicknesses on both sides of the joint. Following the study, some conclusions are derived for the weld offsets.

Hydrogen mitigation in submerged arc welding

NASA Astrophysics Data System (ADS)

Klimowicz, Steven

With the role of hydrogen in weld metal well understood in its relation to cold cracking, there has been a push to produce welds with lower and lower diffusible hydrogen contents. The push for lower diffusible hydrogen contents has placed pressure on consumables manufactures to create consumables that can achieve the requirements for lower diffusible hydrogen content. Currently EM12K flux is produced so that it can achieve below 4 ml of diffusible hydrogen for every 100g of weld metal deposited (ml/100g) for submerged arc welding (SAW). The recent trend for industry is to preferentially achieve diffusible hydrogen contents below 3 ml/100g. Making it necessary to find a way to modify the flux to achieve a lower diffusible hydrogen content for the welds it produces. To achieve this goal a two phase plan was developed. The first phase was to characterize the entire welding system for hydrogen. Since the goal of the project is hydrogen mitigation, any amount of hydrogen that could be reduced is helpful and therefore must first be discovered. Sources of hydrogen may be found by analyzing the welding wire and base metal, as well as breaking the flux down into its components and production steps. The wire was analyzed for total hydrogen content as was the base metal. The flux and its components were analyzed using differential thermal analysis-simultaneous thermal analysis (DTA-STA) and later vacuum degassing for moisture content. The analysis of the wire showed that the copper coating on the wire was the largest contributor of hydrogen. There was lubricant present on the wire surface as well, but it did not contribute as much as the copper coating. It was found that a simple low temperature baking of the wire was enough to remove the lubricant and coating moisture. The base metal was found to have a similar total hydrogen content to that of the wire. The breakdown of the flux and production process for moisture content analysis revealed that the production process

Computerized adaptive control weld skate with CCTV weld guidance project

NASA Technical Reports Server (NTRS)

Wall, W. A.

1976-01-01

This report summarizes progress of the automatic computerized weld skate development portion of the Computerized Weld Skate with Closed Circuit Television (CCTV) Arc Guidance Project. The main goal of the project is to develop an automatic welding skate demonstration model equipped with CCTV weld guidance. The three main goals of the overall project are to: (1) develop a demonstration model computerized weld skate system, (2) develop a demonstration model automatic CCTV guidance system, and (3) integrate the two systems into a demonstration model of computerized weld skate with CCTV weld guidance for welding contoured parts.

Friction welding.

NASA Technical Reports Server (NTRS)

Moore, T. J.

1972-01-01

Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

Advanced Welding Concepts

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2010-01-01

Four advanced welding techniques and their use in NASA are briefly reviewed in this poster presentation. The welding techniques reviewed are: Solid State Welding, Friction Stir Welding (FSW), Thermal Stir Welding (TSW) and Ultrasonic Stir Welding.

Friction plug welding

NASA Technical Reports Server (NTRS)

Takeshita, Riki (Inventor); Hibbard, Terry L. (Inventor)

2001-01-01

Friction plug welding (FPW) usage is advantageous for friction stir welding (FSW) hole close-outs and weld repairs in 2195 Al--Cu--Li fusion or friction stir welds. Current fusion welding methods of Al--Cu--Li have produced welds containing varied defects. These areas are found by non-destructive examination both after welding and after proof testing. Current techniques for repairing typically small (<0.25) defects weaken the weldment, rely heavily on welders' skill, and are costly. Friction plug welding repairs increase strength, ductility and resistance to cracking over initial weld quality, without requiring much time or operator skill. Friction plug welding while pulling the plug is advantageous because all hardware for performing the weld can be placed on one side of the workpiece.

Vacuum Attachment for XRF Scanner

NASA Technical Reports Server (NTRS)

Schramm, Harry F.; Kaiser, Bruce

2005-01-01

Vacuum apparatuses have been developed for increasing the range of elements that can be identified by use of x-ray fluorescent (XRF) scanners of the type mentioned in the two immediately preceding articles. As a consequence of the underlying physical principles, in the presence of air, such an XRF scanner is limited to analysis of chlorine and elements of greater atomic number. When the XRF scanner is operated in a vacuum, it extends the range of analysis to lower atomic numbers - even as far as aluminum and sodium. Hence, more elements will be available for use in XRF labeling of objects as discussed in the two preceding articles. The added benefits of the extended capabilities also have other uses for NASA. Detection of elements of low atomic number is of high interest to the aerospace community. High-strength aluminum alloys will be easily analyzed for composition. Silicon, a major contaminant in certain processes, will be detectable before the process is begun, possibly eliminating weld or adhesion problems. Exotic alloys will be evaluated for composition prior to being placed in service where lives depend on them. And in the less glamorous applications, such as bolts and fasteners, substandard products and counterfeit items will be evaluated at the receiving function and never allowed to enter the operation

Fatigue induced cracking in aluminum LN-2 shroud of 39 foot vacuum chamber

NASA Technical Reports Server (NTRS)

Edwards, A. A.

1984-01-01

Fourteen years after completion of Ford's 39-foot space simulation chamber, leaks began to appear in its LN2 shroud. Although the shroud had been tight since its acceptance, cracks appeared in 1983 in some of the field welds of the one inch tubes which interconnect the LN2 panels. The resulting leaks were large enough to prevent pump down to high vacuum and could be heard easily when the chamber was at ambient conditions. New cracks appeared during each thermal cycle making it impossible to utilize the chamber for thermal vacuum testing. The analysis presented here implies that many, if not all, of the aluminum LN2 shrouds now in use may be in various stages of fatigue failure. The probability is high that fatigue cracks are working through the aluminum tubing in heat-affected zones of some field welds. The cracks may not be apparent yet, but after the shroud has experienced a certain number of thermal cycles these cracks will work through the material and become serious leaks. Fortunately, appropriate planning, analysis, and checking can, with a relatively small expenditure of money, help to avoid large and unexpected shroud failures and keep the chamber operational as long as it is needed.

Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

NASA Technical Reports Server (NTRS)

Looney, Alan

1991-01-01

Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.

Friction Stir Welding

NASA Technical Reports Server (NTRS)

Nunes, Arthur C., Jr.

2008-01-01

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

Alternate Welding Processes for In-Service Welding

DOT National Transportation Integrated Search

2009-04-24

Conducting weld repairs and attaching hot tap tees onto pressurized pipes has the advantage of avoiding loss of service and revenue. However, the risks involved with in-service welding need to be managed by ensuring that welding is performed in a rep...

Thermal Stir Welding: A New Solid State Welding Process

NASA Technical Reports Server (NTRS)

Ding, R. Jeffery; Munafo, Paul M. (Technical Monitor)

2002-01-01

Thermal Stir Shielding is a revolutionary new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating and stirring functions are independent allowing more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Automated Welding System

NASA Technical Reports Server (NTRS)

Bayless, E. O.; Lawless, K. G.; Kurgan, C.; Nunes, A. C.; Graham, B. F.; Hoffman, D.; Jones, C. S.; Shepard, R.

1993-01-01

Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.

Factors affecting weld root morphology in laser keyhole welding

NASA Astrophysics Data System (ADS)

Frostevarg, Jan

2018-02-01

Welding production efficiency is usually optimised if full penetration can be achieved in a single pass. Techniques such as electron and laser beam welding offer deep high speed keyhole welding, especially since multi-kilowatt lasers became available. However, there are limitations for these techniques when considering weld imperfections such as weld cap undercuts, interior porosity or humps at the root. The thickness of sheets during full penetration welding is practically limited by these root humps. The mechanisms behind root morphology formation are not yet satisfactory understood. In this paper root humping is studied by reviewing previous studies and findings and also by sample examination and process observation by high speed imaging. Different process regimes governing root quality are presented, categorized and explained. Even though this study mainly covers laser beam and laser arc hybrid welding, the presented findings can generally be applied full penetration welding in medium to thick sheets, especially the discussion of surface tension effects. As a final result of this analysis, a map of methods to optimise weld root topology is presented.

The effect of welding parameters on penetration in GTA welds

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shirali, A.A.; Mills, K.C.

1993-07-01

The effect of various welding parameters on the penetration of GTA welds has been investigated. Increases in welding speed were found to reduce penetration; however, increases in welding current were observed to increase the penetration in high sulfur (HS) casts and decrease penetration in low sulfur (LS) steels. Plots of penetration as a function of increasing linear energy (the heat supplied per unit length of weld) revealed a similar trend with increased penetration in HS casts, but the penetration in LS casts was unaffected by increases in linear energy. These results support the Burgardt-Heiple proposition that changes in welding parametersmore » on penetration can be explained in terms of their effect, sequentially, on the temperature gradient and the Marangoni forces operating in the weld pool. Increases in arc length were found to decrease weld penetration regardless of the sulfur concentration of the steel, and the effects of electrode geometry and welding position on weld penetration were also investigated.« less

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 49 Transportation 3 2013-10-01 2013-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 3 2011-10-01 2011-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 49 Transportation 3 2012-10-01 2012-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

49 CFR 195.228 - Welds and welding inspection: Standards of acceptability.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 49 Transportation 3 2014-10-01 2014-10-01 false Welds and welding inspection: Standards of... SAFETY TRANSPORTATION OF HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.228 Welds and welding inspection: Standards of acceptability. (a) Each weld and welding must be inspected to insure compliance with...

Forming Completely Penetrated Welded T-joints when Pulsed Arc Welding

NASA Astrophysics Data System (ADS)

Krampit, N. Yu; Krampit, M. A.; Sapozhkov, A. S.

2016-04-01

The paper is focused on revealing the influence of welding parameters on weld formation when pulsed arc welding. As an experimental sample a T-joint over 10 mm was selected. Welding was carried out in flat position, which required no edge preparation but provided mono-directional guaranteed root penetration. The following parameters of welding were subjected to investigation: gap in the joint, wire feed rate and incline angles of the torch along and across the weld axis. Technological recommendations have been made with respect to pulsed arc welding; the cost price of product manufacturing can be reduced on their basis due to reduction of labor input required by machining, lowering consumption of welding materials and electric power.

Parametric study in weld mismatch of longitudinally welded SSME HPFTP inlet

NASA Technical Reports Server (NTRS)

Min, J. B.; Spanyer, K. L.; Brunair, R. M.

1991-01-01

Welded joints are an essential part of pressure vessels such as the Space Shuttle Main Engine (SSME) Turbopumps. Defects produced in the welding process can be detrimental to weld performance. Recently, review of the SSME high pressure fuel turbopump (HPFTP) titanium inlet x rays revealed several weld discrepancies such as penetrameter density issues, film processing discrepancies, weld width discrepancies, porosity, lack of fusion, and weld offsets. Currently, the sensitivity of welded structures to defects is of concern. From a fatigue standpoint, weld offset may have a serious effect since local yielding, in general, aggravates cyclic stress effects. Therefore, the weld offset issue is considered. Using the finite element method and mathematical formulations, parametric studies were conducted to determine the influence of weld offsets and a variation of weld widths in longitudinally welded cylindrical structures with equal wall thickness on both sides of the joint. From the study, the finite element results and theoretical solutions are presented.

Deconvoluting the Friction Stir Weld Process for Optimizing Welds

NASA Technical Reports Server (NTRS)

Schneider, Judy; Nunes, Arthur C.

2008-01-01

In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

Welding IV.

ERIC Educational Resources Information Center

Allegheny County Community Coll., Pittsburgh, PA.

Instructional objectives and performance requirements are outlined in this course guide for Welding IV, a competency-based course in advanced arc welding offered at the Community College of Allegheny County to provide students with proficiency in: (1) single vee groove welding using code specifications established by the American Welding Society…

Welding.

ERIC Educational Resources Information Center

Lehigh County Area Vocational-Technical School, Schnecksville, PA.

This curriculum guide provides materials for a 12-unit secondary course in welding. Purpose stated for the flexible entry and exit course is to help students master manipulative skills to develop successful welding techniques and to gain an understanding of the specialized tools and equipment used in the welding field. Units cover oxyacetylene…

Effects of Fusion Tack Welds on Self-Reacting Friction Stir Welds

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Pendleton, M. L.; Brooke, S. A.; Russell, C. K.

2012-01-01

In order to know whether fusion tack welds would affect the strength of self-reacting friction stir seam welds in 2195-T87 aluminum alloy, the fracture stresses of 144 tensile test coupons cut from 24 welded panels containing segments of friction stir welds were measured. Each of the panels was welded under unique processing conditions. A measure of the effect of the tack welds for each panel was devised. An analysis of the measures of the tack weld effect supported the hypothesis that fusion tack welds do not affect the strength of self-reacting friction stir welds to a 5% level of confidence.

Manganese and welding fume exposure and control in construction.

PubMed

Meeker, John D; Susi, Pam; Flynn, Michael R

2007-12-01

Overexposure to welding fume constituents, particularly manganese, is of concern in the construction industry due to the prevalence of welding and the scarcity of engineering controls. The control effectiveness of a commercially available portable local exhaust ventilation (LEV) unit was assessed. It consisted of a portable vacuum and a small bell-shaped hood connected by a flexible 2 inch (50.8 mm) diameter hose, in both experimental and field settings. The experimental testing was done in a semienclosed booth at a pipefitter training facility. Five paired trials of LEV control vs. no control, each approximately 1 hr in duration and conducted during two successive welds of 6 inch (152.4 mm) diameter carbon steel pipe were run in random order. Breathing zone samples were collected outside the welding hood during each trial. In the field scenario, full-shift breathing zone samples were collected from two pipefitters welding carbon steel pipe for a chiller installation on a commercial construction project. Eight days of full-shift sampling were conducted on both workers (n = 16), and the LEV was used by one of the two workers on an alternating basis for 7 of the days. All samples were collected with personal sample pumps calibrated at 2 L/min. Filter cassettes were analyzed for total particulate and manganese concentration by a certified laboratory. In the experimental setting, use of the portable LEV resulted in a 75% reduction in manganese exposure (mean 13 microg/m(3) vs. 51 microg/m(3); p < 0.05) and a 60% reduction in total particulate (mean 0.74 mg/m(3) vs. 1.83 mg/m(3); p < 0.05). In the field setting, LEV use resulted in a 53% reduction in manganese exposure (geometric mean 46 microg/m(3) vs. 97 microg/m(3); p < 0.05) but only a 10% reduction in total particulate (geometric mean 4.5 mg/m(3) vs. 5.0 mg/m(3); p > 0.05). These results demonstrate that LEV use can reduce manganese exposure associated with welding tasks in construction.

Welding Curriculum.

ERIC Educational Resources Information Center

Alaska State Dept. of Education, Juneau. Div. of Adult and Vocational Education.

This competency-based curriculum guide is a handbook for the development of welding trade programs. Based on a survey of Alaskan welding employers, it includes all competencies a student should acquire in such a welding program. The handbook stresses the importance of understanding the principles associated with the various elements of welding.…

Active weld control

NASA Technical Reports Server (NTRS)

Powell, Bradley W.; Burroughs, Ivan A.

1994-01-01

Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.

Refurbishment of a 39 foot thermal vacuum chamber

NASA Technical Reports Server (NTRS)

Edwards, Arthur A.

1994-01-01

The 39' thermal vacuum chamber at Space Systems/Loral has been used to test numerous spacecraft including those of the GOES, Intelsat, Insat, Superbird, N-Star, NATO and other programs. Ten years ago, the aluminum LN2 shroud experienced serious fatigue failures in the field welded jumper tubing, effectively shutting down the chamber for vacuum testing. The problem was repaired at the time, but new failures began to reappear a few months ago and are now occurring at a rate that suggests that the shroud may again become inoperable. Consequently, Space Systems/Loral is spending in excess of $6 million to replace the shroud and the existing LN2 equipment with a new, state of the art cryogenic system. In May, 1994, a contract was awarded to remove the existing shroud and LN2 pumping system and replace it with a gravity fed shroud and distribution system. Included in the contract are eight skid mounted gaseous nitrogen pumping systems capable of controlling shroud zone temperatures between +150 C and -180 C. The project is scheduled to be completed in April 1995.

Optimization of Multilayer Laminated Film and Absorbent of Vacuum Insulation Panel for Use at High Temperature

NASA Astrophysics Data System (ADS)

Araki, Kuninari; Echigoya, Wataru; Tsuruga, Toshimitsu; Kamoto, Daigorou; Matsuoka, Shin-Ichi

For the energy saving regulation and larger capacity, Vacuum Insulation Panel (VIP) has been used in refrigerators with urethane foam in recent years. VIP for low temperature is constructed by laminated plastic film, using heat welding of each neighboring part for keeping vacuum, so that the performance decrement is very large under high temperature. But recently high efficiency insulation material is desired for high temperature water holding devices (automatic vending machine, heat pump water heater, electric hot-water pot water, etc.), and we especially focused on cost and ability of the laminated plastic film and absorbent for high temperature VIP. We measured the heatproof temperature of plastic films and checked the amount of water vapor and out coming gas on temperature-programmed adsorption in absorbent. These results suggest the suitable laminated film and absorbent system for VIP use at high temperature, and the long-term reliability was evaluated by measuring thermal conductivity of high temperature. As a result it was found that high-retort pouch of CPP (cast polypropylene film) and adding of aluminum coating are the most suitable materials for use in the welded layers of high-temperature VIPs (105°C).

Weld bead profile of laser welding dissimilar joints stainless steel

NASA Astrophysics Data System (ADS)

Mohammed, Ghusoon R.; Ishak, M.; Aqida, S. N.; Abdulhadi, Hassan A.

2017-10-01

During the process of laser welding, the material consecutively melts and solidifies by a laser beam with a peak high power. Several parameters such as the laser energy, pulse frequency, pulse duration, welding power and welding speed govern the mode of the welding process. The aim of this paper is to investigate the effect of peak power, incident angle, and welding speed on the weld bead geometry. The first investigation in this context was conducted using 2205-316L stainless steel plates through the varying of the welding speed from 1.3 mm/s to 2.1 mm/s. The second investigation was conducted by varying the peak power from 1100 W to 1500 W. From the results of the experiments, the welding speed and laser power had a significant effect on the geometry of the weld bead, and the variation in the diameter of the bead pulse-size. Due to the decrease in the heat input, welding speed affected penetration depth more than bead width, and a narrow width of heat affected zone was achieved ranging from 0.2 to 0.5 mm. Conclusively, weld bead geometry dimensions increase as a function of peak power; at over 1350 W peak power, the dimensions lie within 30 μm.

Thermal Stir Welding: A New Solid State Welding Process

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey

2003-01-01

Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Thermal Stir Welding: A New Solid State Welding Process

NASA Technical Reports Server (NTRS)

Ding, R. Jeffrey; Munafo, Paul M. (Technical Monitor)

2002-01-01

Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

Effect of welding position on porosity formation in aluminum alloy welds

NASA Technical Reports Server (NTRS)

Haryung, J.; Wroth, R. S.

1967-01-01

Program investigates the effects of varied welding positions on weld qualities. Progressive changes in bead geometry occur as the weld plane angle is varied from upslope to downslope. The gravitational effect on the weld puddle varies greatly with welding position.

Sustainability of Welding Process through Bobbin Friction Stir Welding

NASA Astrophysics Data System (ADS)

Sued, M. K.; Samsuri, S. S. M.; Kassim, M. K. A. M.; Nasir, S. N. N. M.

2018-03-01

Welding process is in high demand, which required a competitive technology to be adopted. This is important for sustaining the needs of the joining industries without ignoring the impact of the process to the environment. Friction stir welding (FSW) is stated to be benefitting the environment through low energy consumption, which cannot be achieved through traditional arc welding. However, this is not well documented, especially for bobbin friction stir welding (BFSW). Therefore, an investigation is conducted by measuring current consumption of the machine during the BFSW process. From the measurement, different phases of BFSW welding process and its electrical demand are presented. It is found that in general total energy in BFSW is about 130kW inclusive of all identified process phases. The phase that utilise for joint formation is in weld phase that used the highest total energy of 120kWs. The recorded total energy is still far below the traditional welding technology and the conventional friction stir welding (CFSW) energy demand. This indicates that BFSW technology with its vast benefit able to sustain the joining technology in near future.

Enabling high speed friction stir welding of aluminum tailor welded blanks

NASA Astrophysics Data System (ADS)

Hovanski, Yuri

Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding (FSW) has traditionally been applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translate to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum FSW components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability using a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.

The Influence of Friction Stir Weld Tool Form and Welding Parameters on Weld Structure and Properties: Nugget Bulge in Self-Reacting Friction Stir Welds

NASA Technical Reports Server (NTRS)

Schneider, Judy; Nunes, Arthur C., Jr.; Brendel, Michael S.

2010-01-01

Although friction stir welding (FSW) was patented in 1991, process development has been based upon trial and error and the literature still exhibits little understanding of the mechanisms determining weld structure and properties. New concepts emerging from a better understanding of these mechanisms enhance the ability of FSW engineers to think about the FSW process in new ways, inevitably leading to advances in the technology. A kinematic approach in which the FSW flow process is decomposed into several simple flow components has been found to explain the basic structural features of FSW welds and to relate them to tool geometry and process parameters. Using this modelling approach, this study reports on a correlation between the features of the weld nugget, process parameters, weld tool geometry, and weld strength. This correlation presents a way to select process parameters for a given tool geometry so as to optimize weld strength. It also provides clues that may ultimately explain why the weld strength varies within the sample population.

Research on the Effect of Welding Speed on the Quality of Welding Seam Based on the Local Dry Underwater Welding

NASA Astrophysics Data System (ADS)

Liu, Lei; Chen, Wu; Wang, Huagang; Ba, Jinyu; Li, Bing

2017-12-01

The repair of nuclear spent fuel pool has a high requirement for the quality of welding, the welding speed directly affects the quality of the weld when local dry automatic underwater welding is used to repair the damaged surface. Under the condition of the same condition, the local dry automatic underwater welding test was carried out under the condition of the same welding condition. Taking the 20cm as the experimental condition, after massive experiments show that when the welding speed is approximately 48cm/min the weld quality is high, meeting the design requirements, based on the double layer shrinkage nozzle chamber of local dry underwater automatic welding.

Assessment of Corona/Arcing Hazard for Electron Beam Welding in Space Shuttle Bay at LEO for ISWE: Test Results

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Russell, C.; Vaughn, J.; Stocks, C.; ODell, D.; Bhat, B.

1996-01-01

Test welds were made in argon over a range of pressures from 10-5 to 10-3 torr (the latter pressure an order of magnitude above pressures anticipated in the space shuttle bay during welding) with and without plasma on 304 stainless steel, 6Al-4V titanium, and 5456 aluminum in search of any possible unwanted electrical discharges. Only a faint steady glow of beam-excited atoms around the electron beam and sometimes extending out into the vacuum chamber was observed. No signs of current spiking or of any potentially dangerous electrical discharge were found.

Automatic orbital GTAW welding: Highest quality welds for tomorrow's high-performance systems

NASA Technical Reports Server (NTRS)

Henon, B. K.

1985-01-01

Automatic orbital gas tungsten arc welding (GTAW) or TIG welding is certain to play an increasingly prominent role in tomorrow's technology. The welds are of the highest quality and the repeatability of automatic weldings is vastly superior to that of manual welding. Since less heat is applied to the weld during automatic welding than manual welding, there is less change in the metallurgical properties of the parent material. The possibility of accurate control and the cleanliness of the automatic GTAW welding process make it highly suitable to the welding of the more exotic and expensive materials which are now widely used in the aerospace and hydrospace industries. Titanium, stainless steel, Inconel, and Incoloy, as well as, aluminum can all be welded to the highest quality specifications automatically. Automatic orbital GTAW equipment is available for the fusion butt welding of tube-to-tube, as well as, tube to autobuttweld fittings. The same equipment can also be used for the fusion butt welding of up to 6 inch pipe with a wall thickness of up to 0.154 inches.

Influence of Welding Process and Post Weld Heat Treatment on Microstructure and Pitting Corrosion Behavior of Dissimilar Aluminium Alloy Welds

NASA Astrophysics Data System (ADS)

Venkata Ramana, V. S. N.; Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

Welding of dissimilar Aluminum alloy welds is becoming important in aerospace, shipbuilding and defence applications. In the present work, an attempt has been made to weld dissimilar aluminium alloys using conventional gas tungsten arc welding (GTAW) and friction stir welding (FSW) processes. An attempt was also made to study the effect of post weld heat treatment (T4 condition) on microstructure and pitting corrosion behaviour of these welds. Results of the present investigation established the differences in microstructures of the base metals in T4 condition and in annealed conditions. It is evident that the thickness of the PMZ is relatively more on AA2014 side than that of AA6061 side. In FS welds, lamellar like shear bands are well noticed on the top of the stir zone. The concentration profile of dissimilar friction stir weld in T4 condition revealed that no diffusion has taken place at the interface. Poor Hardness is observed in all regions of FS welds compared to that of GTA welds. Pitting corrosion resistance of the dissimilar FS welds in all regions was improved by post weld heat treatment.

Space processing applications of ion beam technology. [surface finishing, welding, milling and film deposition

NASA Technical Reports Server (NTRS)

Grodzka, P. G.

1977-01-01

Ion thruster engines for spacecraft propulsion can serve as ion beam sources for potential space processing applications. The advantages of space vacuum environments and the possible gravity effects on thruster ion beam materials operations such as thin film growth, ion milling, and surface texturing were investigated. The direct gravity effect on sputter deposition and vapor deposition processes are discussed as well as techniques for cold and warm welding.

High-Speed Friction-Stir Welding To Enable Aluminum Tailor-Welded Blanks

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hovanski, Yuri; Upadhyay, Piyush; Carsley, John

Current joining technologies for automotive aluminum alloys are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding has been traditionally applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translatemore » to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum welded components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability utilizing a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.« less

Laser weld jig

DOEpatents

Van Blarigan, Peter; Haupt, David L.

1982-01-01

A system is provided for welding a workpiece (10, FIG. 1) along a predetermined weld line (12) that may be of irregular shape, which includes the step of forming a lip (32) on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members (34, 36). Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space (17) at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reuseable jig (24) forming the lip, and with the jig constructed to detachably hold parts (22, 20) to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

Welding Penetration Control of Fixed Pipe in TIG Welding Using Fuzzy Inference System

NASA Astrophysics Data System (ADS)

Baskoro, Ario Sunar; Kabutomori, Masashi; Suga, Yasuo

This paper presents a study on welding penetration control of fixed pipe in Tungsten Inert Gas (TIG) welding using fuzzy inference system. The welding penetration control is essential to the production quality welds with a specified geometry. For pipe welding using constant arc current and welding speed, the bead width becomes wider as the circumferential welding of small diameter pipes progresses. Having welded pipe in fixed position, obviously, the excessive arc current yields burn through of metals; in contrary, insufficient arc current produces imperfect welding. In order to avoid these errors and to obtain the uniform weld bead over the entire circumference of the pipe, the welding conditions should be controlled as the welding proceeds. This research studies the intelligent welding process of aluminum alloy pipe 6063S-T5 in fixed position using the AC welding machine. The monitoring system used a charge-coupled device (CCD) camera to monitor backside image of molten pool. The captured image was processed to recognize the edge of molten pool by image processing algorithm. Simulation of welding control using fuzzy inference system was constructed to simulate the welding control process. The simulation result shows that fuzzy controller was suitable for controlling the welding speed and appropriate to be implemented into the welding system. A series of experiments was conducted to evaluate the performance of the fuzzy controller. The experimental results show the effectiveness of the control system that is confirmed by sound welds.

Versatile Friction Stir Welding/Friction Plug Welding System

NASA Technical Reports Server (NTRS)

Carter, Robert

2006-01-01

A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.

Monitoring the quality of welding based on welding current and ste analysis

NASA Astrophysics Data System (ADS)

Mazlan, Afidatusshimah; Daniyal, Hamdan; Izzani Mohamed, Amir; Ishak, Mahadzir; Hadi, Amran Abdul

2017-10-01

Qualities of welding play an important part in industry especially in manufacturing field. Post-welding non-destructive test is one of the importance process to ensure the quality of welding but it is time consuming and costly. To reduce the chance of defects, online monitoring had been utilized by continuously sense some of welding parameters and predict welding quality. One of the parameters is welding current, which is rich of information but lack of study focus on extract them at signal analysis level. This paper presents the analysis of welding current using Short Time Energy (STE) signal processing to quantify the pattern of the current. GMAW set with carbon steel specimens are used in this experimental study with high-bandwidth and high sampling rate oscilloscope capturing the welding current. The results indicate welding current as signatures have high correlation with the welding process. Continue with STE analysis, the value below 5000 is declare as good welding, meanwhile the STE value more than 6000 is contained defect.

Characteristics of Extra Narrow Gap Weld of HSLA Steel Welded by Single-Seam per Layer Pulse Current GMA Weld Deposition

NASA Astrophysics Data System (ADS)

Agrawal, B. P.; Ghosh, P. K.

2017-03-01

Butt weld joints are produced using pulse current gas metal arc welding process by employing the technique of centrally laid multi-pass single-seam per layer weld deposition in extra narrow groove of thick HSLA steel plates. The weld joints are prepared by using different combination of pulse parameters. The selection of parameter of pulse current gas metal arc welding is done considering a summarized influence of simultaneously interacting pulse parameters defined by a dimensionless hypothetical factor ϕ. The effect of diverse pulse parameters on the characteristics of weld has been studied. Weld joint is also prepared by using commonly used multi-pass multi-seam per layer weld deposition in conventional groove. The extra narrow gap weld joints have been found much superior to the weld joint prepared by multi-pass multi-seam per layer deposition in conventional groove with respect to its metallurgical characteristics and mechanical properties.

Fusion welding process

DOEpatents

Thomas, Kenneth C.; Jones, Eric D.; McBride, Marvin A.

1983-01-01

A process for the fusion welding of nickel alloy steel members wherein a ferrite containing pellet is inserted into a cavity in one member and melted by a welding torch. The resulting weld nugget, a fusion of the nickel containing alloy from the members to be welded and the pellet, has a composition which is sufficiently low in nickel content such that ferrite phases occur within the weld nugget, resulting in improved weld properties. The steel alloys encompassed also include alloys containing carbon and manganese, considered nickel equivalents.

Fusion zone microstructure and porosity in electron beam welds of an α+β titanium alloy

NASA Astrophysics Data System (ADS)

Mohandas, T.; Banerjee, D.; Kutumba Rao, V. V.

1999-03-01

The effect of electron beam welding parameters on fusion zone (FZ) microstructure and porosity in a Ti -6.8 Al -3.42 Mo -1.9 Zr -0.21 Si alloy (Russian designation VT 9) has been investigated. It has been observed that the FZ grain width increased continuously with increase in heat input when the base metal was in the β heat-treated condition, while in the α+β heat-treated base metal welds, the FZ grain width increased only after a threshold energy input. The difference is attributed to both the weld thermal cycle and the pinning effect of equiaxed primary alpha on grain growth in the heat-affected zone (HAZ) of α+β heat-treated base metal. Postweld heat treatment (PWHT) in the subtransus and supertransus regions did not alter the columnar grain morphology in the FZ, possibly due to the lack of enough driving force for the formation of new grains by the breaking up of the columnar grains and grain boundary movement for grain growth. As the PWHTs were conducted in a furnace, the role of thermal gradients can be ruled out. Intragranular microstructure in the aswelded condition consisted of hexagonal martensite. The scale of the martensite laths depended on welding speed. The highest porosity was observed at intermediate welding speeds. At low speeds, a majority of pores formed at the fusion boundary, while at high speeds, occurrence of porosity was maximum at the weld center. The trends on porosity can be explained on the basis of solubility of hydrogen in titanium as a function of temperature and the influence of weld thermal cycle on nucleation, growth, and escape of hydrogen gas bubbles. The porosity at slow welding speeds is low because sufficient time exists for the nucleation, growth, and escape of hydrogen gas bubbles, while insufficient time exists for the nucleation of gas bubbles at high welding speeds. The effect of pickling of joint surface, vacuum annealing of the base metal, and successive remelting of the weld metal has also been investigated.

Effect of thermal exposure, forming, and welding on high-temperature, dispersion-strengthened aluminum alloy: Al-8Fe-1V-2Si

NASA Technical Reports Server (NTRS)

Kennedy, J. R.; Gilman, P. S.; Zedalis, M. S.; Skinner, D. J.; Peltier, J. M.

1991-01-01

The feasibility of applying conventional hot forming and welding methods to high temperature aluminum alloy, Al-8Fe-1V-2Si (FVS812), for structural applications and the effect of thermal exposure on mechanical properties were determined. FVS812 (AA8009) sheet exhibited good hot forming and resistance welding characteristics. It was brake formed to 90 deg bends (0.5T bend radius) at temperatures greater than or equal to 390 C (730 F), indicating the feasibility of fabricating basic shapes, such as angles and zees. Hot forming of simple contoured-flanged parts was demonstrated. Resistance spot welds with good static and fatigue strength at room and elevated temperatures were readily produced. Extended vacuum degassing during billet fabrication reduced porosity in fusion and resistance welds. However, electron beam welding was not possible because of extreme degassing during welding, and gas-tungsten-arc welds were not acceptable because of severely degraded mechanical properties. The FVS812 alloy exhibited excellent high temperature strength stability after thermal exposures up to 315 C (600 F) for 1000 h. Extended billet degassing appeared to generally improve tensile ductility, fatigue strength, and notch toughness. But the effects of billet degassing and thermal exposure on properties need to be further clarified. The manufacture of zee-stiffened, riveted, and resistance-spot-welded compression panels was demonstrated.

Intelligent Weld Manufacturing: Role of Integrated Computational Welding Engineering

DOE PAGES

David, Stan A.; Chen, Jian; Feng, Zhili; ...

2017-12-02

A master welder uses his sensory perceptions to evaluate the process and connect them with his/her knowledge base to take the necessary corrective measures with his/her acquired skills to make a good weld. All these actions must take place in real time. Success depends on intuition and skills, and the procedure is labor-intensive and frequently unreliable. The solution is intelligent weld manufacturing. The ultimate goal of intelligent weld manufacturing would involve sensing and control of heat source position, weld temperature, weld penetration, defect formation and ultimately control of microstructure and properties. This involves a solution to a problem (welding) withmore » many highly coupled and nonlinear variables. The trend is to use an emerging tool known as intelligent control. This approach enables the user to choose a desirable end factor such as properties, defect control, or productivity to derive the selection of process parameters such as current, voltage, or speed to provide for appropriate control of the process. Important elements of intelligent manufacturing are sensing and control theory and design, process modeling, and artificial intelligence. Significant progress has been made in all these areas. Integrated computational welding engineering (ICWE) is an emerging field that will aid in the realization of intelligent weld manufacturing. The paper will discuss the progress in process modeling, microstructure, properties, and process control and automation and the importance of ICWE. Also, control and automation strategies for friction stir welding will be discussed.« less

Intelligent Weld Manufacturing: Role of Integrated Computational Welding Engineering

DOE Office of Scientific and Technical Information (OSTI.GOV)

David, Stan A.; Chen, Jian; Feng, Zhili

A master welder uses his sensory perceptions to evaluate the process and connect them with his/her knowledge base to take the necessary corrective measures with his/her acquired skills to make a good weld. All these actions must take place in real time. Success depends on intuition and skills, and the procedure is labor-intensive and frequently unreliable. The solution is intelligent weld manufacturing. The ultimate goal of intelligent weld manufacturing would involve sensing and control of heat source position, weld temperature, weld penetration, defect formation and ultimately control of microstructure and properties. This involves a solution to a problem (welding) withmore » many highly coupled and nonlinear variables. The trend is to use an emerging tool known as intelligent control. This approach enables the user to choose a desirable end factor such as properties, defect control, or productivity to derive the selection of process parameters such as current, voltage, or speed to provide for appropriate control of the process. Important elements of intelligent manufacturing are sensing and control theory and design, process modeling, and artificial intelligence. Significant progress has been made in all these areas. Integrated computational welding engineering (ICWE) is an emerging field that will aid in the realization of intelligent weld manufacturing. The paper will discuss the progress in process modeling, microstructure, properties, and process control and automation and the importance of ICWE. Also, control and automation strategies for friction stir welding will be discussed.« less

Welding polarity effects on weld spatters and bead geometry of hyperbaric dry GMAW

NASA Astrophysics Data System (ADS)

Xue, Long; Wu, Jinming; Huang, Junfen; Huang, Jiqiang; Zou, Yong; Liu, Jian

2016-03-01

Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding(GMAW) experiments with direct current electrode positive(DCEP) and direct current electrode negative(DCEN) operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows: an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.

Weld procedure produces quality welds for thick sections of Hastelloy-X

NASA Technical Reports Server (NTRS)

Flens, F. J.; Fletcher, C. W.; Glasier, L. F., Jr.

1967-01-01

Welding program produces premium quality, multipass welds in heavy tube sections of Hastelloy-X. It develops semiautomatic tungsten/inert gas procedures, weld wire procurement specifications material weld properties, welder-operator training, and nondestructive testing inspection techniques and procedures.

Basic Welding Skills. Welding Module 1. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a six-unit module in basic welding skills. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: the welding profession, personal safety,…

Advanced Welding Applications

NASA Technical Reports Server (NTRS)

Ding, Robert J.

2010-01-01

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding

PubMed Central

Fethke, Nathan B.; Peters, Thomas M.; Leonard, Stephanie; Metwali, Mahmoud; Mudunkotuwa, Imali A.

2016-01-01

The welding of shear stud connectors to structural steel in construction requires a prolonged stooped posture that exposes ironworkers to biomechanical and welding fume hazards. In this study, biomechanical and welding fume exposures during stud welding using conventional methods were compared to exposures associated with use of a prototype system that allowed participants to weld from an upright position. The effect of base material (i.e. bare structural beam versus galvanized decking) on welding fume concentration (particle number and mass), particle size distribution, and particle composition was also explored. Thirty participants completed a series of stud welding simulations in a local apprenticeship training facility. Use of the upright system was associated with substantial reductions in trunk inclination and the activity levels of several muscle groups. Inhalable mass concentrations of welding fume (averaged over ~18min) when using conventional methods were high (18.2mg m−3 for bare beam; 65.7mg m−3 for through deck), with estimated mass concentrations of iron (7.8mg m−3 for bare beam; 15.8mg m−3 for through deck), zinc (0.2mg m−3 for bare beam; 15.8mg m−3 for through deck), and manganese (0.9mg m−3 for bare beam; 1.5mg m−3 for through deck) often exceeding the American Conference of Governmental Industrial Hygienists Threshold Limit Values (TLVs). Number and mass concentrations were substantially reduced when using the upright system, although the total inhalable mass concentration remained above the TLV when welding through decking. The average diameters of the welding fume particles for both bare beam (31±17nm) through deck conditions (34±34nm) and the chemical composition of the particles indicated the presence of metallic nanoparticles. Stud welding exposes ironworkers to potentially high levels of biomechanical loading (primarily to the low back) and welding fume. The upright system used in this study improved exposure levels during

WELDING METHOD

DOEpatents

Cornell, A.A.; Dunbar, J.V.; Ruffner, J.H.

1959-09-29

A semi-automatic method is described for the weld joining of pipes and fittings which utilizes the inert gasshielded consumable electrode electric arc welding technique, comprising laying down the root pass at a first peripheral velocity and thereafter laying down the filler passes over the root pass necessary to complete the weld by revolving the pipes and fittings at a second peripheral velocity different from the first peripheral velocity, maintaining the welding head in a fixed position as to the specific direction of revolution, while the longitudinal axis of the welding head is disposed angularly in the direction of revolution at amounts between twenty minutas and about four degrees from the first position.

Friction stir welding tool and process for welding dissimilar materials

DOEpatents

Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

2013-05-07

A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

Syllabus in Trade Welding.

ERIC Educational Resources Information Center

New York State Education Dept., Albany. Bureau of Secondary Curriculum Development.

The syllabus outlines material for a course two academic years in length (minimum two and one-half hours daily experience) leading to entry-level occupational ability in several welding trade areas. Fourteen units covering are welding, gas welding, oxyacetylene welding, cutting, nonfusion processes, inert gas shielded-arc welding, welding cast…

Latest MIG, TIG arc-YAG laser hybrid welding systems for various welding products

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, Shuho; Watanabe, Masao

2003-03-01

Laser welding is capable of high-efficiency low-strain welding, and so its applications are started to various products. We have also put the high-power YAG laser of up to 10 kW to practical welding use for various products. On the other hand the weakest point of this laser welding is considered to be strict in the welding gap aiming allowance. In order to solve this problem, we have developed hybrid welding of TIG, MIG arc and YAG laser, taking the most advantages of both the laser and arc welding. Since the electrode is coaxial to the optical axis of the YAG laser in this process, it can be applied to welding of various objects. In the coaxial MIG, TIG-YAG welding, in order to make irradiation positions of the YAG laser beams having been guided in a wire or an electrode focused to the same position, the beam transmitted in fibers is separated to form a space between the separated beams, in which the laser is guided. With this method the beam-irradiating area can be brought near or to the arc-generating point. This enables welding of all directions even for the member of a three-dimensional shape. This time we carried out welding for various materials and have made their welding of up to 1 mm or more in welding groove gap possible. We have realized high-speed 1-pass butt welding of 4m/min in welding speed with the laser power of 3 kW for an aluminum alloy plate of approximately 4 mm thick. For a mild steel plate also we have realized butt welding of 1m/min with 5 kW for 6 mm thick. Further, in welding of stainless steel we have shown its welding possibility, by stabilizing the arc with the YAG laser in the welding atmosphere of pure argon, and shown that this welding is effective in high-efficiency welding of various materials. Here we will report the fundamental welding performances and applications to various objects for the coaxial MIG, TIG-YAG welding we have developed.

Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

NASA Technical Reports Server (NTRS)

Adams, Glynn; Venable, Richard; Lawless, Kirby

2003-01-01

Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

The technology and welding joint properties of hybrid laser-tig welding on thick plate

NASA Astrophysics Data System (ADS)

Shenghai, Zhang; Yifu, Shen; Huijuan, Qiu

2013-06-01

The technologies of autogenous laser welding and hybrid laser-TIG welding are used on thick plate of high strength lower alloy structural steel 10CrNiMnMoV in this article. The unique advantages of hybrid laser-TIG welding is summarized by comparing and analyzing the process parameters and welding joints of autogenous laser welding laser welding and hybrid laser-TIG welding. With the optimal process parameters of hybrid welding, the good welding joint without visible flaws can be obtained and its mechanical properties are tested according to industry standards. The results show that the hybrid welding technology has certain advantages and possibility in welding thick plates. It can reduce the demands of laser power, and it is significant for lowering the aspect ratio of weld during hybrid welding, so the gas in the molten pool can rise and escape easily while welding thick plates. Therefore, the pores forming tendency decreases. At the same time, hybrid welding enhances welding speed, and optimizes the energy input. The transition and grain size of the microstructure of hybrid welding joint is better and its hardness is higher than base material. Furthermore, its tensile strength and impact toughness is as good as base material. Consequently, the hybrid welding joint can meet the industry needs completely.

Survey of welding processes.

DOT National Transportation Integrated Search

2003-07-01

The current KYTC SPECIAL PROVISION NO. 4 WELDING STEEL BRIDGES prohibits the use of welding processes other than shielded metal arc welding (SMAW) and submerged arc welding (SAW). Nationally, bridge welding is codified under ANSI/AASHTO/AWS D1....

Simplified welding distortion analysis for fillet welding using composite shell elements

NASA Astrophysics Data System (ADS)

Kim, Mingyu; Kang, Minseok; Chung, Hyun

2015-09-01

This paper presents the simplified welding distortion analysis method to predict the welding deformation of both plate and stiffener in fillet welds. Currently, the methods based on equivalent thermal strain like Strain as Direct Boundary (SDB) has been widely used due to effective prediction of welding deformation. Regarding the fillet welding, however, those methods cannot represent deformation of both members at once since the temperature degree of freedom is shared at the intersection nodes in both members. In this paper, we propose new approach to simulate deformation of both members. The method can simulate fillet weld deformations by employing composite shell element and using different thermal expansion coefficients according to thickness direction with fixed temperature at intersection nodes. For verification purpose, we compare of result from experiments, 3D thermo elastic plastic analysis, SDB method and proposed method. Compared of experiments results, the proposed method can effectively predict welding deformation for fillet welds.

Welding Technician

ERIC Educational Resources Information Center

Smith, Ken

2009-01-01

About 95% of all manufactured goods in this country are welded or joined in some way. These welded products range in nature from bicycle handlebars and skyscrapers to bridges and race cars. The author discusses what students need to know about careers for welding technicians--wages, responsibilities, skills needed, career advancement…

METHOD OF OBTAINING AN IMPROVED WELD IN INERT ARC WELDING

DOEpatents

Correy, T.B.

1962-12-11

A method is reported for inert arc welding. An a-c welding current is applied to the workpiece and welding electrode such that the positive portion of each cycle thereof, with the electrode positive, has only sufficient energy to clean the surface of the workpiece and the negative portion of each cycle thereof, with the electrode negative, contains the energy required to weld. (AEC)

Introduction to Welding.

ERIC Educational Resources Information Center

Fortney, Clarence; Gregory, Mike

This curriculum guide provides six units of instruction on basic welding. Addressed in the individual units of instruction are the following topics: employment opportunities for welders, welding safety and first aid, welding tools and equipment, basic metals and metallurgy, basic math and measuring, and procedures for applying for a welding job.…

Reduction of Biomechanical and Welding Fume Exposures in Stud Welding.

PubMed

Fethke, Nathan B; Peters, Thomas M; Leonard, Stephanie; Metwali, Mahmoud; Mudunkotuwa, Imali A

2016-04-01

The welding of shear stud connectors to structural steel in construction requires a prolonged stooped posture that exposes ironworkers to biomechanical and welding fume hazards. In this study, biomechanical and welding fume exposures during stud welding using conventional methods were compared to exposures associated with use of a prototype system that allowed participants to weld from an upright position. The effect of base material (i.e. bare structural beam versus galvanized decking) on welding fume concentration (particle number and mass), particle size distribution, and particle composition was also explored. Thirty participants completed a series of stud welding simulations in a local apprenticeship training facility. Use of the upright system was associated with substantial reductions in trunk inclination and the activity levels of several muscle groups. Inhalable mass concentrations of welding fume (averaged over ~18 min) when using conventional methods were high (18.2 mg m(-3) for bare beam; 65.7 mg m(-3) for through deck), with estimated mass concentrations of iron (7.8 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), zinc (0.2 mg m(-3) for bare beam; 15.8 mg m(-3) for through deck), and manganese (0.9 mg m(-3) for bare beam; 1.5 mg m(-3) for through deck) often exceeding the American Conference of Governmental Industrial Hygienists Threshold Limit Values (TLVs). Number and mass concentrations were substantially reduced when using the upright system, although the total inhalable mass concentration remained above the TLV when welding through decking. The average diameters of the welding fume particles for both bare beam (31±17 nm) through deck conditions (34±34 nm) and the chemical composition of the particles indicated the presence of metallic nanoparticles. Stud welding exposes ironworkers to potentially high levels of biomechanical loading (primarily to the low back) and welding fume. The upright system used in this study improved exposure

Pre-weld heat treatment improves welds in Rene 41

NASA Technical Reports Server (NTRS)

Prager, M.

1968-01-01

Cooling of Rene 41 prior to welding reduces the incidence of cracking during post-weld heat treatment. The microstructure formed during the slow cooling rate favors elevated temperature ductility. Some vestiges of this microstructure are apparently retained during welding and thus enhance strain-age crack resistance in air.

High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks

NASA Astrophysics Data System (ADS)

Hovanski, Yuri; Upadhyay, Piyush; Carsley, John; Luzanski, Tom; Carlson, Blair; Eisenmenger, Mark; Soulami, Ayoub; Marshall, Dustin; Landino, Brandon; Hartfield-Wunsch, Susan

2015-05-01

Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and they have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high volumes. While friction-stir welding (FSW) has been traditionally applied at linear velocities less than 1 m/min, high-volume production applications demand the process be extended to higher velocities more amenable to cost-sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low-to-moderate welding velocities do not directly translate to high-speed linear FSW. Therefore, to facilitate production of high-volume aluminum FSW components, parameters were developed with a minimum welding velocity of 3 m/min. With an emphasis on weld quality, welded blanks were evaluated for postweld formability using a combination of numerical and experimental methods. An evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum TWBs, which provided validation of the numerical and experimental analysis of laboratory-scale tests.

Numerical and experimental determination of weld pool shape during high-power diode laser welding

NASA Astrophysics Data System (ADS)

Klimpel, Andrzej; Lisiecki, Aleksander; Szymanski, Andrzej; Hoult, Anthony P.

2003-10-01

In this paper, results of investigations on the shape of weld pool during High Power Diode Laser (HPDL) welding are presented. The results of tests showed that the shape of weld pool and mechanism of laser welding with a rectangular pattern of 808 nm laser radiation differs distinctly from previous laser welding mechanisms. For all power densities the conduction mode welds were observed and weld pool geometry depends significantly on the welding parameters.

Structure of welded joints obtained by contact weld in nanostructured titanium

NASA Astrophysics Data System (ADS)

Klimenov, V. A.; Klopotov, A. A.; Gnysov, S. F.; Vlasov, V. A.; Lychagin, D. V.; Chumaevskii, A. V.

2015-10-01

The paper presents the research of the weld structure of two Ti specimens of the type VT6 that have nano- and submicrocrystalline structures. Electrical contact welding is used to obtain welds. The acicular structure is formed in the weld area. Two types of defects are detected, namely micropores and microcracks.

Welded joints integrity analysis and optimization for fiber laser welding of dissimilar materials

NASA Astrophysics Data System (ADS)

Ai, Yuewei; Shao, Xinyu; Jiang, Ping; Li, Peigen; Liu, Yang; Liu, Wei

2016-11-01

Dissimilar materials welded joints provide many advantages in power, automotive, chemical, and spacecraft industries. The weld bead integrity which is determined by process parameters plays a significant role in the welding quality during the fiber laser welding (FLW) of dissimilar materials. In this paper, an optimization method by taking the integrity of the weld bead and weld area into consideration is proposed for FLW of dissimilar materials, the low carbon steel and stainless steel. The relationships between the weld bead integrity and process parameters are developed by the genetic algorithm optimized back propagation neural network (GA-BPNN). The particle swarm optimization (PSO) algorithm is taken for optimizing the predicted outputs from GA-BPNN for the objective. Through the optimization process, the desired weld bead with good integrity and minimum weld area are obtained and the corresponding microstructure and microhardness are excellent. The mechanical properties of the optimized joints are greatly improved compared with that of the un-optimized welded joints. Moreover, the effects of significant factors are analyzed based on the statistical approach and the laser power (LP) is identified as the most significant factor on the weld bead integrity and weld area. The results indicate that the proposed method is effective for improving the reliability and stability of welded joints in the practical production.

Weld-Bead Shaver

NASA Technical Reports Server (NTRS)

Guirguis, Kamal; Price, Daniel S.

1990-01-01

Hand-held power tool shaves excess metal from inside circumference of welded duct. Removes excess metal deposited by penetration of tungsten/inert-gas weld or by spatter from electron-beam weld. Produces smooth transition across joint. Easier to use and not prone to overshaving. Also cuts faster, removing 35 in. (89 cm) of weld bead per hour.

Arc Welding of Mg Alloys: Oxide Films, Irregular Weld Shape and Liquation Cracking

NASA Astrophysics Data System (ADS)

Chai, Xiao

The use of Mg alloys for vehicle weight reduction has been increasing rapidly worldwide. Gas-metal arc welding (GMAW) has the potential for mass-production welding of Mg alloys. Recently, the University of Wisconsin demonstrated in bead-on-plate GMAW of Mg alloys that severe spatter can be eliminated by using controlled short circuiting (CSC), and severe hydrogen porosity can be eliminated by removing Mg(OH)2. The present study aimed at actual butt and lap welding of Mg alloys by CSC-GMAW and susceptibility of Mg alloys to weld-edge cracking using the circular-patch welding test. Sound welds were made without spatter and hydrogen porosity butt and lap welding of AZ 31 Mg using CSC-GMAW , with butt welds approaching 100% of the base-metal strength. However, three new significant issues were found to occur easily and degrade the weld quality significantly: 1. formation of oxide films inside butt welds, 2. formation of high crowns on butt welds, and 3. formation of fingers from lap welds. The mechanisms of their formation were established, and the methods for their elimination or reduction were demonstrated. Circular-patch welds were made on most widely used Mg casting alloy AZ91, the most widely used Mg wrought alloy AZ31 with three different Mg filler wires AZ31, AZ61 and AZ92. The susceptibility to cracking along the weld edge was predicted and compared against the experimental results. Such a prediction has not been made for welds of Mg alloys before.

Oxy-Fuel Cutting/Welding. Welding Module 3. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a four-unit module in oxy-fuel cutting and welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: oxyacetylene welding, oxyacetylene…

Welding of Thin Steel Plates by Hybrid Welding Process Combined TIG Arc with YAG Laser

NASA Astrophysics Data System (ADS)

Kim, Taewon; Suga, Yasuo; Koike, Takashi

TIG arc welding and laser welding are used widely in the world. However, these welding processes have some advantages and problems respectively. In order to improve problems and make use of advantages of the arc welding and the laser welding processes, hybrid welding process combined the TIG arc with the YAG laser was studied. Especially, the suitable welding conditions for thin steel plate welding were investigated to obtain sound weld with beautiful surface and back beads but without weld defects. As a result, it was confirmed that the shot position of the laser beam is very important to obtain sound welds in hybrid welding. Therefore, a new intelligent system to monitor the welding area using vision sensor is constructed. Furthermore, control system to shot the laser beam to a selected position in molten pool, which is formed by TIG arc, is constructed. As a result of welding experiments using these systems, it is confirmed that the hybrid welding process and the control system are effective on the stable welding of thin stainless steel plates.

[New welding processes and health effects of welding].

PubMed

La Vecchia, G Marina; Maestrelli, Piero

2011-01-01

This paper describes some of the recent developments in the control technology to enhance capability of Pulse Gas Metal Arc Welding. Friction Stir Welding (FSW) processing has been also considered. FSW is a new solid-state joining technique. Heat generated by friction at the rotating tool softens the material being welded. FSW can be considered a green and energy-efficient technique without deleterious fumes, gas, radiation, and noise. Application of new welding processes is limited and studies on health effects in exposed workers are lacking. Acute and chronic health effects of conventional welding have been described. Metal fume fever and cross-shift decline of lung function are the main acute respiratory effects. Skin and eyes may be affected by heat, electricity and UV radiations. Chronic effects on respiratory system include chronic bronchitis, a benign pneumoconiosis (siderosis), asthma, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders.

Weld analysis and control system

NASA Technical Reports Server (NTRS)

Kennedy, Larry Z. (Inventor); Rodgers, Michael H. (Inventor); Powell, Bradley W. (Inventor); Burroughs, Ivan A. (Inventor); Goode, K. Wayne (Inventor)

1994-01-01

The invention is a Weld Analysis and Control System developed for active weld system control through real time weld data acquisition. Closed-loop control is based on analysis of weld system parameters and weld geometry. The system is adapted for use with automated welding apparatus having a weld controller which is capable of active electronic control of all aspects of a welding operation. Enhanced graphics and data displays are provided for post-weld analysis. The system provides parameter acquisition, including seam location which is acquired for active torch cross-seam positioning. Torch stand-off is also monitored for control. Weld bead and parent surface geometrical parameters are acquired as an indication of weld quality. These parameters include mismatch, peaking, undercut, underfill, crown height, weld width, puddle diameter, and other measurable information about the weld puddle regions, such as puddle symmetry, etc. These parameters provide a basis for active control as well as post-weld quality analysis and verification. Weld system parameters, such as voltage, current and wire feed rate, are also monitored and archived for correlation with quality parameters.

Dual wire welding torch and method

DOEpatents

Diez, Fernando Martinez; Stump, Kevin S.; Ludewig, Howard W.; Kilty, Alan L.; Robinson, Matthew M.; Egland, Keith M.

2009-04-28

A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

Improving the Quality of Welding Seam of Automatic Welding of Buckets Based on TCP

NASA Astrophysics Data System (ADS)

Hu, Min

2018-02-01

Since February 2014, the welding defects of the automatic welding line of buckets have been frequently appeared. The average repair time of each bucket is 26min, which seriously affects the production efficiency and welding quality. We conducted troubleshooting, and found the main reasons for the welding defects of the buckets were the deviations of the center points of the robot tools and the poor quality of the locating welding. We corrected the gripper, welding torch, and accuracy of repeat positioning of robots to control the quality of positioning welding. The welding defect rate of buckets was reduced greatly, ensuring the production efficiency and welding quality.

Electroslag and electrogas welding

NASA Technical Reports Server (NTRS)

Campbell, H. C.

1972-01-01

These two new joining methods perform welding in the vertical position, and therein lies the secret of their impressive advantages in material handling, in weld preparation, in welding speed, in freedom from distortion, and in weld soundness. Once the work has been set in the proper vertical position for welding, no further plate handling is required. The molten filler metal is held in place by copper shoes or dams, and the weld is completed in one pass.

Comparison between hybrid laser-MIG welding and MIG welding for the invar36 alloy

NASA Astrophysics Data System (ADS)

Zhan, Xiaohong; Li, Yubo; Ou, Wenmin; Yu, Fengyi; Chen, Jie; Wei, Yanhong

2016-11-01

The invar36 alloy is suitable to produce mold of composite materials structure because it has similar thermal expansion coefficient with composite materials. In the present paper, the MIG welding and laser-MIG hybrid welding methods are compared to get the more appropriate method to overcome the poor weldability of invar36 alloy. According to the analysis of the experimental and simulated results, it has been proved that the Gauss and cone combined heat source model can characterize the laser-MIG hybrid welding heat source well. The total welding time of MIG welding is 8 times that of hybrid laser-MIG welding. The welding material consumption of MIG welding is about 4 times that of hybrid laser-MIG welding. The stress and deformation simulation indicate that the peak value of deformation during MIG welding is 3 times larger than that of hybrid laser-MIG welding.

Experimental investigation on the weld pool formation process in plasma keyhole arc welding

NASA Astrophysics Data System (ADS)

Van Anh, Nguyen; Tashiro, Shinichi; Van Hanh, Bui; Tanaka, Manabu

2018-01-01

This paper seeks to clarify the weld pool formation process in plasma keyhole arc welding (PKAW). We adopted, for the first time, the measurement of the 3D convection inside the weld pool in PKAW by stereo synchronous imaging of tungsten tracer particles using two sets of x-ray transmission systems. The 2D convection on the weld pool surface was also measured using zirconia tracer particles. Through these measurements, the convection in a wide range of weld pools from the vicinity of the keyhole to the rear region was successfully visualized. In order to discuss the heat transport process in a weld pool, the 2D temperature distribution on the weld pool surface was also measured by two-color pyrometry. The results of the comprehensive experimental measurement indicate that the shear force due to plasma flow is found to be the dominant driving force in the weld pool formation process in PKAW. Thus, heat transport in a weld pool is considered to be governed by two large convective patterns near the keyhole: (1) eddy pairs on the surface (perpendicular to the torch axis), and (2) eddy pairs on the bulk of the weld pool (on the plane of the torch). They are formed with an equal velocity of approximately 0.35 m s-1 and are mainly driven by shear force. Furthermore, the flow velocity of the weld pool convection becomes considerably higher than that of other welding processes, such as TIG welding and GMA welding, due to larger plasma flow velocity.

Narrow gap laser welding

DOEpatents

Milewski, John O.; Sklar, Edward

1998-01-01

A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables.

Narrow gap laser welding

DOEpatents

Milewski, J.O.; Sklar, E.

1998-06-02

A laser welding process including: (a) using optical ray tracing to make a model of a laser beam and the geometry of a joint to be welded; (b) adjusting variables in the model to choose variables for use in making a laser weld; and (c) laser welding the joint to be welded using the chosen variables. 34 figs.

Effects of welding technology on welding stress based on the finite element method

NASA Astrophysics Data System (ADS)

Fu, Jianke; Jin, Jun

2017-01-01

Finite element method is used to simulate the welding process under four different conditions of welding flat butt joints. Welding seams are simulated with birth and death elements. The size and distribution of welding residual stress is obtained in the four kinds of welding conditions by Q345 manganese steel plate butt joint of the work piece. The results shown that when using two-layers welding,the longitudinal and transverse residual stress were reduced;When welding from Middle to both sides,the residual stress distribution will change,and the residual stress in the middle of the work piece was reduced.

Analysis and Comparison of Aluminum Alloy Welded Joints Between Metal Inert Gas Welding and Tungsten Inert Gas Welding

NASA Astrophysics Data System (ADS)

Zhao, Lei; Guan, Yingchun; Wang, Qiang; Cong, Baoqiang; Qi, Bojin

2015-09-01

Surface contamination usually occurs during welding processing and it affects the welds quality largely. However, the formation of such contaminants has seldom been studied. Effort was made to study the contaminants caused by metal inert gas (MIG) welding and tungsten inert gas (TIG) welding processes of aluminum alloy, respectively. SEM, FTIR and XPS analysis was carried out to investigate the microstructure as well as surface chemistry. These contaminants were found to be mainly consisting of Al2O3, MgO, carbide and chromium complexes. The difference of contaminants between MIG and TIG welds was further examined. In addition, method to minimize these contaminants was proposed.

Electric arc welding gun

DOEpatents

Luttrell, Edward; Turner, Paul W.

1978-01-01

This invention relates to improved apparatus for arc welding an interior joint formed by intersecting tubular members. As an example, the invention is well suited for applications where many similar small-diameter vertical lines are to be welded to a long horizontal header. The improved apparatus includes an arc welding gun having a specially designed welding head which is not only very compact but also produces welds that are essentially free from rolled-over solidified metal. The welding head consists of the upper end of the barrel and a reversely extending electrode holder, or tip, which defines an acute angle with the barrel. As used in the above-mentioned example, the gun is positioned to extend upwardly through the vertical member and the joint to be welded, with its welding head disposed within the horizontal header. Depending on the design of the welding head, the barrel then is either rotated or revolved about the axis of the vertical member to cause the electrode to track the joint.

Performance of repair welds on aged Cr-Mo piping girth welds

NASA Astrophysics Data System (ADS)

Viswanathan, R.; Gandy, D. W.

1999-10-01

This article documents the results of an industry survey of weld repair practices and describes the results of experimental evaluations performed on service-aged 21/4 Cr-1Mo steel piping using SMAW with both conventional postweld heat treatments and temper bead repair techniques. The overall results of this program provide substantial evidence that service-aged piping systems can be successfully weld repaired with and without postweld heat treatments and that life extension by several decades is achievable under the right design and repair conditions. Weld repairs performed on degraded exservice welds resulted in restoration or improvement of tensile and creep properties. Microhardness test results within the heat-affected zone of each weldment indicated that the temper bead weld repairs produced only slightly higher peak hardness values than those measured for the fully postweld heat treated repairs. Finally, in terms of toughness, temper bead weld repairs consistently produced higher impact properties than those measured for the postweld heat treated weldments. Gas tungsten arc weld repairs with postweld heat treatment resulted in the best combination of tensile strength, uniform microhardness distribution across the weld, Charpy toughness, and creep rupture life.

A novel weld seam detection method for space weld seam of narrow butt joint in laser welding

NASA Astrophysics Data System (ADS)

Shao, Wen Jun; Huang, Yu; Zhang, Yong

2018-02-01

Structured light measurement is widely used for weld seam detection owing to its high measurement precision and robust. However, there is nearly no geometrical deformation of the stripe projected onto weld face, whose seam width is less than 0.1 mm and without misalignment. So, it's very difficult to ensure an exact retrieval of the seam feature. This issue is raised as laser welding for butt joint of thin metal plate is widely applied. Moreover, measurement for the seam width, seam center and the normal vector of the weld face at the same time during welding process is of great importance to the welding quality but rarely reported. Consequently, a seam measurement method based on vision sensor for space weld seam of narrow butt joint is proposed in this article. Three laser stripes with different wave length are project on the weldment, in which two red laser stripes are designed and used to measure the three dimensional profile of the weld face by the principle of optical triangulation, and the third green laser stripe is used as light source to measure the edge and the centerline of the seam by the principle of passive vision sensor. The corresponding image process algorithm is proposed to extract the centerline of the red laser stripes as well as the seam feature. All these three laser stripes are captured and processed in a single image so that the three dimensional position of the space weld seam can be obtained simultaneously. Finally, the result of experiment reveals that the proposed method can meet the precision demand of space narrow butt joint.

High Temperature Analysis of Aluminum-Lithium 2195 Alloy to Aid in the Design of Improved Welding Techniques

NASA Technical Reports Server (NTRS)

Talia, George E.; Widener, Christian

1996-01-01

Aluminum-lithium alloys have extraordinary properties. The addition of lithium to an aluminum alloy decreases its density, while making large increases in its strength and hardness. The down side is that they are unstable at higher temperatures, and are subsequently difficult to weld or even manufacture. Martin Marietta, though, developed an aluminum-lithium alloy 2195 that was reported to have exceptional properties and good weldability. Thus, it was chosen as the alloy for the space shuttles super light external tank. Unfortunately, welding 2195 has turned out to be much more of a challenge than anticipated. Thus, research has been undergone in order to understand the mechanisms that are causing the welding problems. Gas reactions have been observed to be detrimental to weld strength. Water vapor has often been identified as having a significant role in these reactions. Nitrogen, however, has also been shown to have a direct correlation to porosity. These reactions were suspected as being complex and responsible for the two main problems of welding 2195. One, the initial welds of 2195 are much weaker than the parent metal. Second, each subsequent welding pass increases the size and number of cracks and porosity, yielding significant reductions in strength. Consequently, the objective of this research was to characterize the high-temperature reactions of 2195 in order to understand the mechanisms for crack growth and the formation of porosity in welds. In order to accomplish that goal, an optical hot-stage microscope, HSM, was used to observe those reactions as they occurred. Surface reactions of 2195 were observed in a variety of environments, such as air, vacuum, nitrogen and helium. For comparison, some samples of Al-2219 were also observed. Some of the reacted surfaces were then analyzed on a scanning electron microscope, SEM. Additionally, a gas chromatograph was used to analyze the gaseous products of the high temperature reactions.

Study of Mechanical Properties and Characterization of Pipe Steel welded by Hybrid (Friction Stir Weld + Root Arc Weld) Approach

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lim, Yong Chae; Sanderson, Samuel; Mahoney, Murray

Friction stir welding (FSW) has recently attracted attention as an alternative construction process for gas/oil transportation applications due to advantages compared to fusion welding techniques. A significant advantage is the ability of FSW to weld the entire or nearly the entire wall thickness in a single pass, while fusion welding requires multiple passes. However, when FSW is applied to a pipe or tube geometry, an internal back support anvil is required to resist the plunging forces exerted during FSW. Unfortunately, it may not be convenient or economical to use internal backing support due to limited access for some applications. Tomore » overcome this issue, ExxonMobil recently developed a new concept, combining root arc welding and FSW. That is, a root arc weld is made prior to FSW that supports the normal loads associated with FSW. In the present work, mechanical properties of a FSW + root arc welded pipe steel are reported including microstructure and microhardness.« less

Moisture contamination and welding parameter effects on flux cored arc welding diffusible hydrogen

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kiefer, J.J.

1994-12-31

Gas metal arc (GMAW) and flux cored arc (FCAW) welding are gas shielded semiautomatic processes widely used for achieving high productivity in steel fabrication. Contamination of the shielding has can occur due to poorly maintained gas distribution systems. Moisture entering as a gas contaminant is a source of hydrogen that can cause delayed cold cracking in welds. Limiting heat-affected zone hardness is one method of controlling cracking. Even this is based on some assumptions about the hydrogen levels in the weld. A study was conducted to investigate the effect of shielding gas moisture contamination and welding parameters on the diffusiblemore » hydrogen content of gas shielded flux cored arc welding. The total wire hydrogen of various electrodes was also tested and compared to the diffusible weld hydrogen. An empirical equation has been developed that estimates the diffusible hydrogen in weld metal for gas shielded flux cored arc welding. The equation is suitable for small diameter electrodes and welding parameter ranges commonly used for out-of-position welding. by combining this with the results from the total wire hydrogen tests, it is possible to estimate diffusible hydrogen directly from measured welding parameters, shielding gas dew point, and total hydrogen of the consumable. These equations are also useful for evaluating the effect of welding procedure variations from known baseline conditions.« less

Certification of a weld produced by friction stir welding

DOEpatents

Obaditch, Chris; Grant, Glenn J

2013-10-01

Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

Vacuum force

NASA Astrophysics Data System (ADS)

Han, Yongquan

2015-03-01

To study on vacuum force, we must clear what is vacuum, vacuum is a space do not have any air and also ray. There is not exist an absolute the vacuum of space. The vacuum of space is relative, so that the vacuum force is relative. There is a certain that vacuum vacuum space exists. In fact, the vacuum space is relative, if the two spaces compared to the existence of relative vacuum, there must exist a vacuum force, and the direction of the vacuum force point to the vacuum region. Any object rotates and radiates. Rotate bend radiate- centripetal, gravity produced, relative gravity; non gravity is the vacuum force. Gravity is centripetal, is a trend that the objects who attracted wants to Centripetal, or have been do Centripetal movement. Any object moves, so gravity makes the object curve movement, that is to say, the radiation range curve movement must be in the gravitational objects, gravity must be existed in non vacuum region, and make the object who is in the region of do curve movement (for example: The earth moves around the sun), or final attracted in the form gravitational objects, and keep relatively static with attract object. (for example: objects on the earth moves but can't reach the first cosmic speed).

Penetration in GTA welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Heiple, C.R.; Burgardt, P.

1990-01-01

The size and shape of the weld bead produced in GTA welding depends on the magnitude and distribution of the energy incident on the workpiece surfaces as well as the dissipation of that energy in the workpiece. The input energy is largely controllable through the welding parameters selected, however the dissipation of that energy in the workpiece is less subject to control. Changes in energy dissipation can produce large changes in weld shape or penetration. Heat transport away from the weld pool is almost entirely by conduction, but heat transport in the weld pool is more complicated. Heat conduction throughmore » the liquid is an important component, but heat transport by convection (mass transport) is often the dominant mechanism. Convective heat transport is directional and changes the weld pool shape from that produced by conduction alone. Surface tension gradients are often the dominant forces driving fluid flow in GTA weld pools. These gradients are sensitive functions of weld pool chemistry and the energy input distribution to the weld. Experimental and theoretical work conducted primarily in the past decade has greatly enhanced our understanding of weld pool fluid flow, the forces which drive it, and its effects on weld pool shape. This work is reviewed here. While less common, changes in energy dissipation through the unmelted portion of the workpiece can also affect fusion zone shape or penetration. These effects are also described. 41 refs., 9 figs.« less

Ultrasonic Stir Welding

NASA Technical Reports Server (NTRS)

Nabors, Sammy

2015-01-01

NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

Application of welding science to welding engineering: A lumped parameter gas metal arc welding dynamic process model

DOE Office of Scientific and Technical Information (OSTI.GOV)

Murray, P.E.; Smartt, H.B.; Johnson, J.A.

1997-12-31

We develop a model of the depth of penetration of the weld pool in gas metal arc welding (GMAW) which demonstrates interaction between the arc, filler wire and weld pool. This model is motivated by the observations of Essers and Walter which suggest a relationship between droplet momentum and penetration depth. A model of gas metal arc welding was augmented to include an improved model of mass transfer and a simple model of accelerating droplets in a plasma jet to obtain the mass and momentum of impinging droplets. The force of the droplets and depth of penetration is correlated bymore » a dimensionless linear relation used to predict weld pool depth for a range of values of arc power and contact tip to workpiece distance. Model accuracy is examined by comparing theoretical predictions and experimental measurements of the pool depth obtained from bead on plate welds of carbon steel in an argon rich shielding gas. Moreover, theoretical predictions of pool depth are compared to the results obtained from the heat conduction model due to Christensen et al. which suggest that in some cases the momentum of impinging droplets is a better indicator of the depth of the weld pool and the presence of a deep, narrow penetration.« less

The effects of welded joint characteristics on its properties in HDPE thermal fusion welding

NASA Astrophysics Data System (ADS)

Dai, Hongbin; Peng, Jun

2017-05-01

In this paper, PE100 pipes with the diameter of 200 mm and the thickness of 11.9 mm were used as material. The welded joints were obtained in different welding pressures with the optimal welding temperature of 220∘C. Reheating process on the welded joints with the temperature of 130∘C was carried out. The joints exhibited X-type, and the cause of X-type joints was discussed. The temperature field in the forming process of welded joints was measured, and tensile and bending tests on welded joints were carried out. The fracture surface of welded joints was observed by scanning electron microscopy (SEM), and crystallinity calculation was taken by X-ray diffraction (XRD). The mechanism of X-type weld profile effects on welded joints properties was analyzed. It was concluded that the mechanical properties of welded joints decrease with the reduced X distance between lines.

[Hygienic evaluation of new welding processes and welding materials].

PubMed

Gorban', L N

1990-01-01

The possibility of contaminating the breathing air zone with hazardous substances in manual and semi-automated welding increases with the intensity of their formation in the arc zone. This necessitates more comprehensive data on both the specific excreta and the formation intensity of the most hazardous substances, such as hard and gaseous compounds of welding aerosols, with due account of the welding regimen used and electrode diameter, wires, etc. When calculating the effectiveness of both local and general ventilation systems in welding shops, a possibility of a specific one-way hazardous action of some chemical substances (e.g. chromium, fluorine, etc.) should be taken into account.

Design of a welded joint for robotic, on-orbit assembly of space trusses

NASA Astrophysics Data System (ADS)

Rule, William K.

1992-12-01

. welding. &A low gravity environment has been found to have very minor effects on the welding processes appropriate for this application. This is based on tests run on-orbit as well as low gravity environments achieved by flying aircraft in parabolic trajectories. It appears that a modified form of gas tungsten arc welding (GTAW) will be most appropriate for welding together structures on-oribt. *The process has been modified to work in a vacuum by providing gas to the arc zone by means of a hollow tungsten electrode with special shielding. -A commercial tube welding head has been successfully modified for use on-orbit with a gas leakage rate of approximately 2.5 liters/min. To develop as realistic a joint as possible, a specific truss structure was selected on which to base the design. The structure considered was based on the 120 foot diameter aerobrake tetrahedral truss structure. %The truss members were assumed to consist of graphite/epoxy tubes. Also, it was assumed that the nodes were constructed of 2219-T87 aluminum alloy. The magnitude of the member load assumed for design purposes was 100 kips.

Programmable Positioner For Spot Welding

NASA Technical Reports Server (NTRS)

Roden, William A.

1989-01-01

Welding station mechanized by installing preset indexing system and gear drive. Mechanism includes a low-cost, versatile, single-axis motion control and motor drive to provide fully-automatic weld sequencing and spot-to-spot spacing. Welding station relieves operator of some difficult, tedious tasks and increases both productivity and quality of welds. Results in welds of higher quality and greater accuracy, fewer weld defects, and faster welding operation.

WELDING TORCH

DOEpatents

Correy, T.B.

1961-10-01

A welding torch into which water and inert gas are piped separately for cooling and for providing a suitable gaseous atmosphere is described. A welding electrode is clamped in the torch by a removable collet sleeve and a removable collet head. Replacement of the sleeve and head with larger or smaller sleeve and head permits a larger or smaller welding electrode to be substituted on the torch. (AEC)

The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading.

PubMed

Araque, Oscar; Arzola, Nelson; Hernández, Edgar

2018-04-12

This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe.

The Effect of Weld Reinforcement and Post-Welding Cooling Cycles on Fatigue Strength of Butt-Welded Joints under Cyclic Tensile Loading

PubMed Central

Arzola, Nelson; Hernández, Edgar

2018-01-01

This research deals with the fatigue behavior of butt-welded joints, by considering the geometry and post-welding cooling cycles, as a result of cooling in quiet air and immersed in water. ASTM A-36 HR structural steel was used as the base metal for the shielded metal arc welding (SMAW) process with welding electrode E6013. The welding reinforcement was 1 mm and 3 mm, respectively; axial fatigue tests were carried out to determine the life and behavior in cracks propagation of the tested welded joints, mechanical characterization tests of properties in welded joints such as microhardness, Charpy impact test and metallographic analysis were carried out. The latter were used as input for the analysis by finite elements which influence the initiation and propagation of cracks and the evaluation of stress intensity factors (SIF). The latter led to obtaining the crack propagation rate and the geometric factor. The tested specimens were analyzed, by taking photographs of the cracks at its beginning in order to make a count of the marks at the origin of the crack. From the results obtained and the marks count, the fatigue crack growth rate and the influence of the cooling media on the life of the welded joint are validated, according to the experimental results. It can be concluded that the welded joints with a higher weld reinforcement have a shorter fatigue life. This is due to the stress concentration that occurs in the vicinity of the weld toe. PMID:29649117

Quantification of Microtexture at Weld Nugget of Friction Stir-Welded Carbon Steel

NASA Astrophysics Data System (ADS)

Husain, Md M.; Sarkar, R.; Pal, T. K.; Ghosh, M.; Prabhu, N.

2017-05-01

Friction stir welding of C-Mn steel was carried out under 800-1400 rpm tool rotation. Tool traversing speed of 50 mm/min remained same for all joints. Effect of thermal state and deformation on texture and microstructure at weld nugget was investigated. Weld nugget consisted of ferrite + bainite/Widmanstatten ferrite with different matrix grain sizes depending on peak temperature. A texture around ( ϕ 2 = 0°, φ = 30°, ϕ 2 = 45°) was developed at weld nugget. Grain boundary misorientation at weld nugget indicated that continuous dynamic recrystallization influenced the development of fine equiaxed grain structure. Pole figures and orientation distribution function were used to determine crystallographic texture at weld nugget and base metal. Shear texture components D1, D2 and F were present at weld nugget. D1 shear texture was more prominent among all. Large number of high-angle grain boundaries ( 60-70%) was observed at weld nugget and was the resultant of accumulation of high amount of dislocation, followed by subgrain formation.

Optically controlled welding system

NASA Technical Reports Server (NTRS)

Gordon, Stephen S. (Inventor)

1988-01-01

An optically controlled welding system wherein a welding torch having through-the-torch viewing capabilities is provided with an optical beam splitter to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder to make the welding torch responsive thereto. Other features include an actively cooled electrode holder which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm, and a weld pool contour detector comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom, being characteristic of a penetrated or unpenetrated condition of the weld pool.

Fluid Flow Phenomena during Welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Wei

2011-01-01

MOLTEN WELD POOLS are dynamic. Liquid in the weld pool in acted on by several strong forces, which can result in high-velocity fluid motion. Fluid flow velocities exceeding 1 m/s (3.3 ft/s) have been observed in gas tungsten arc (GTA) welds under ordinary welding conditions, and higher velocities have been measured in submerged arc welds. Fluid flow is important because it affects weld shape and is related to the formation of a variety of weld defects. Moving liquid transports heat and often dominates heat transport in the weld pool. Because heat transport by mass flow depends on the direction andmore » speed of fluid motion, weld pool shape can differ dramatically from that predicted by conductive heat flow. Temperature gradients are also altered by fluid flow, which can affect weld microstructure. A number of defects in GTA welds have been attributed to fluid flow or changes in fluid flow, including lack of penetration, top bead roughness, humped beads, finger penetration, and undercutting. Instabilities in the liquid film around the keyhole in electron beam and laser welds are responsible for the uneven penetration (spiking) characteristic of these types of welds.« less

Multihole Arc-Welding Orifice

NASA Technical Reports Server (NTRS)

Swaim, Benji D.

1989-01-01

Modified orifice for variable-polarity plasma-arc welding directs welding plume so it creates clean, even welds on both Inconel(R) and aluminum alloys. Includes eight holes to relieve back pressure in plasma. Quality of welds on ferrous and nonferrous alloys improved as result.

Narrow groove welding gas diffuser assembly and welding torch

DOEpatents

Rooney, Stephen J.

2001-01-01

A diffuser assembly is provided for narrow groove welding using an automatic gas tungsten arc welding torch. The diffuser assembly includes a manifold adapted for adjustable mounting on the welding torch which is received in a central opening in the manifold. Laterally extending manifold sections communicate with a shield gas inlet such that shield gas supplied to the inlet passes to gas passages of the manifold sections. First and second tapered diffusers are respectively connected to the manifold sections in fluid communication with the gas passages thereof. The diffusers extend downwardly along the torch electrode on opposite sides thereof so as to release shield gas along the length of the electrode and at the distal tip of the electrode. The diffusers are of a transverse width which is on the order of the thickness of the electrode so that the diffusers can, in use, be inserted into a narrow welding groove before and after the electrode in the direction of the weld operation.

Alternating-Polarity Arc Welding

NASA Technical Reports Server (NTRS)

Schwinghamer, R. J.

1987-01-01

Brief reversing polarity of welding current greatly improves quality of welds. NASA technical memorandum recounts progress in art of variable-polarity plasma-arc (VPPA) welding, with emphasis on welding of aluminum-alloy tanks. VPPA welders offer important advantages over conventional single-polarity gas/tungsten arc welders.

Fast, Nonspattering Inert-Gas Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.

1991-01-01

Proposed welding technique combines best features of metal (other than tungsten)/inert-gas welding, plasma arc welding, and tungsten/inert-gas welding. Advantages include: wire fed to weld joint preheated, therefore fed at high speed without spattering; high-frequency energy does not have to be supplied to workpiece to initiate welding; size of arc gap not critical, power-supply control circuit adjusts voltage across gap to compensate for changes; only low gas-flow rate needed; welding electrode replaced easily as prefabricated assembly; external wire-feeding manipulator not needed; and welding process relatively forgiving of operator error.

Influence of the arc plasma parameters on the weld pool profile in TIG welding

NASA Astrophysics Data System (ADS)

Toropchin, A.; Frolov, V.; Pipa, A. V.; Kozakov, R.; Uhrlandt, D.

2014-11-01

Magneto-hydrodynamic simulations of the arc and fluid simulations of the weld pool can be beneficial in the analysis and further development of arc welding processes and welding machines. However, the appropriate coupling of arc and weld pool simulations needs further improvement. The tungsten inert gas (TIG) welding process is investigated by simulations including the weld pool. Experiments with optical diagnostics are used for the validation. A coupled computational model of the arc and the weld pool is developed using the software ANSYS CFX. The weld pool model considers the forces acting on the motion of the melt inside and on the surface of the pool, such as Marangoni, drag, electromagnetic forces and buoyancy. The experimental work includes analysis of cross-sections of the workpieces, highspeed video images and spectroscopic measurements. Experiments and calculations have been performed for various currents, distances between electrode and workpiece and nozzle diameters. The studies show the significant impact of material properties like surface tension dependence on temperature as well as of the arc structure on the weld pool behaviour and finally the weld seam depth. The experimental weld pool profiles and plasma temperatures are in good agreement with computational results.

Optically controlled welding system

NASA Technical Reports Server (NTRS)

Gordon, Stephen S. (Inventor)

1989-01-01

An optically controlled welding system (10) wherein a welding torch (12) having through-the-torch viewing capabilities is provided with an optical beam splitter (56) to create a transmitted view and a reflective view of a welding operation. These views are converted to digital signals which are then processed and utilized by a computerized robotic welder (15) to make the welding torch responsive thereto. Other features includes an actively cooled electrode holder (26) which minimizes a blocked portion of the view by virtue of being constructed of a single spoke or arm (28) and a weld pool contour detector (14) comprising a laser beam directed onto the weld pool with the position of specular radiation reflected therefrom being characteristic of a penetrated or unpenetrated condition of the weld pool.

Vision-based weld pool boundary extraction and width measurement during keyhole fiber laser welding

NASA Astrophysics Data System (ADS)

Luo, Masiyang; Shin, Yung C.

2015-01-01

In keyhole fiber laser welding processes, the weld pool behavior is essential to determining welding quality. To better observe and control the welding process, the accurate extraction of the weld pool boundary as well as the width is required. This work presents a weld pool edge detection technique based on an off axial green illumination laser and a coaxial image capturing system that consists of a CMOS camera and optic filters. According to the difference of image quality, a complete developed edge detection algorithm is proposed based on the local maximum gradient of greyness searching approach and linear interpolation. The extracted weld pool geometry and the width are validated by the actual welding width measurement and predictions by a numerical multi-phase model.

Coil Welding Aid

NASA Technical Reports Server (NTRS)

Wiesenbach, W. T.; Clark, M. C.

1983-01-01

Positioner holds coil inside cylinder during tack welding. Welding aid spaces turns of coil inside cylinder and applies contact pressure while coil is tack-welded to cylinder. Device facilitates fabrication of heat exchangers and other structures by eliminating hand-positioning and clamping of individual coil turns.

Characterization of weld imperfections in 2195 Al-Li alloy: Experimental approaches towards mechanisms

NASA Astrophysics Data System (ADS)

Zaidi, Anwer Arif

1997-10-01

of repair and E-stop cracks suggest interdendritic melting as the main factor responsible for cracking during welding. Heating in nitrogen reveals a weight loss (TGA) characteristic of an outgassing process before the weight gain thought to be associated with a nitrogen reaction takes over; hence the outgassing process, whatever it is, is thought to be independent of the nitrogen reaction. If the nitrogen contribution to porosity generation is then assigned to the promotion of local melting, the fusion zone fracture of laser weld beads subject to residual stress and heated under nitrogen atmosphere, but not under vacuum nor helium, is explicable. If this has been accomplished, cracking during welding is understood, and control procedures should be implicit in the understanding. (Abstract shortened by UMI.)

Grinding Parts For Automatic Welding

NASA Technical Reports Server (NTRS)

Burley, Richard K.; Hoult, William S.

1989-01-01

Rollers guide grinding tool along prospective welding path. Skatelike fixture holds rotary grinder or file for machining large-diameter rings or ring segments in preparation for welding. Operator grasps handles to push rolling fixture along part. Rollers maintain precise dimensional relationship so grinding wheel cuts precise depth. Fixture-mounted grinder machines surface to quality sufficient for automatic welding; manual welding with attendant variations and distortion not necessary. Developed to enable automatic welding of parts, manual welding of which resulted in weld bead permeated with microscopic fissures.

In-flight and laboratory vacuum-friction test results

NASA Technical Reports Server (NTRS)

Devine, E. J.; Evans, H. E.; Leasure, W. A.

1973-01-01

Coefficient of friction measurements were made for six unlubricated metal couples exposed to the space environment aboard the OV-1-13 spacecraft and exposed to laboratory vacuum. Materials studied included mutually soluble, partially soluble, and insoluble metal combinations. Two samples of each material couple were tested in space and in the laboratory using the disk and rider technique. Linear velocity was 0.10 cm/s (2.5 in/min) and rider normal load was 4.45 N (1 lb) for the gold versus silver couples and 8.90 N (2lb) for the other combinations. Results showed that friction data obtained in a clean ion-pumped laboratory vacuum of 10 to the minus 10 power materials with low mutual solubility can be correlated to operation in the vicinity of a typical scientific spacecraft that is exposed to an ambient pressure as low as 10 to the minus 12 power torr. The expected increase in coefficient of friction with solubility was shown. Material couples with high mutual solubility present the hazard of unpredictable drastic friction increase in orbit which may not be evident in laboratory testing at levels down to 10 to the minus 10 power torr. It was also shown that gross cold welding of unlubricated metals exposed to a satellite environment does not occur.

VPPA weld model evaluation

NASA Technical Reports Server (NTRS)

Mccutcheon, Kimble D.; Gordon, Stephen S.; Thompson, Paul A.

1992-01-01

NASA uses the Variable Polarity Plasma Arc Welding (VPPAW) process extensively for fabrication of Space Shuttle External Tanks. This welding process has been in use at NASA since the late 1970's but the physics of the process have never been satisfactorily modeled and understood. In an attempt to advance the level of understanding of VPPAW, Dr. Arthur C. Nunes, Jr., (NASA) has developed a mathematical model of the process. The work described in this report evaluated and used two versions (level-0 and level-1) of Dr. Nunes' model, and a model derived by the University of Alabama at Huntsville (UAH) from Dr. Nunes' level-1 model. Two series of VPPAW experiments were done, using over 400 different combinations of welding parameters. Observations were made of VPPAW process behavior as a function of specific welding parameter changes. Data from these weld experiments was used to evaluate and suggest improvements to Dr. Nunes' model. Experimental data and correlations with the model were used to develop a multi-variable control algorithm for use with a future VPPAW controller. This algorithm is designed to control weld widths (both on the crown and root of the weld) based upon the weld parameters, base metal properties, and real-time observation of the crown width. The algorithm exhibited accuracy comparable to that of the weld width measurements for both aluminum and mild steel welds.

Welding arc plasma physics

NASA Technical Reports Server (NTRS)

Cain, Bruce L.

1990-01-01

The problems of weld quality control and weld process dependability continue to be relevant issues in modern metal welding technology. These become especially important for NASA missions which may require the assembly or repair of larger orbiting platforms using automatic welding techniques. To extend present welding technologies for such applications, NASA/MSFC's Materials and Processes Lab is developing physical models of the arc welding process with the goal of providing both a basis for improved design of weld control systems, and a better understanding of how arc welding variables influence final weld properties. The physics of the plasma arc discharge is reasonably well established in terms of transport processes occurring in the arc column itself, although recourse to sophisticated numerical treatments is normally required to obtain quantitative results. Unfortunately the rigor of these numerical computations often obscures the physics of the underlying model due to its inherent complexity. In contrast, this work has focused on a relatively simple physical model of the arc discharge to describe the gross features observed in welding arcs. Emphasis was placed of deriving analytic expressions for the voltage along the arc axis as a function of known or measurable arc parameters. The model retains the essential physics for a straight polarity, diffusion dominated free burning arc in argon, with major simplifications of collisionless sheaths and simple energy balances at the electrodes.

A History of Welding on the Space Shuttle Main Engine (1975 to 2010)

NASA Technical Reports Server (NTRS)

Zimmerman, Frank R.; Russell, Carolyn K.

2010-01-01

The Space Shuttle Main Engine (SSME) is a high performance, throttleable, liquid hydrogen fueled rocket engine. High thrust and specific impulse (Isp) are achieved through a staged combustion engine cycle, combined with high combustion pressure (approx.3000psi) generated by the two-stage pump and combustion process. The SSME is continuously throttleable from 67% to 109% of design thrust level. The design criteria for this engine maximize performance and weight, resulting in a 7,800 pound rocket engine that produces over a half million pounds of thrust in vacuum with a specific impulse of 452/sec. It is the most reliable rocket engine in the world, accumulating over one million seconds of hot-fire time and achieving 100% flight success in the Space Shuttle program. A rocket engine with the unique combination of high reliability, performance, and reusability comes at the expense of manufacturing simplicity. Several innovative design features and fabrication techniques are unique to this engine. This is as true for welding as any other manufacturing process. For many of the weld joints it seemed mean cheating physics and metallurgy to meet the requirements. This paper will present a history of the welding used to produce the world s highest performance throttleable rocket engine.

Thermo-Mechanical Analysis of a Single-Pass Weld Overlay and Girth Welding in Lined Pipe

NASA Astrophysics Data System (ADS)

Obeid, Obeid; Alfano, Giulio; Bahai, Hamid

2017-08-01

The paper presents a nonlinear heat-transfer and mechanical finite-element (FE) analyses of a two-pass welding process of two segments of lined pipe made of a SUS304 stainless steel liner and a C-Mn steel pipe. The two passes consist of the single-pass overlay welding (inner lap weld) of the liner with the C-Mn steel pipe for each segment and the single-pass girth welding (outer butt weld) of the two segments. A distributed power density of the moving welding torch and a nonlinear heat-transfer coefficient accounting for both radiation and convection have been used in the analysis and implemented in user subroutines for the FE code ABAQUS. The modeling procedure has been validated against previously published experimental results for stainless steel and carbon steel welding separately. The model has been then used to determine the isotherms induced by the weld overlay and the girth welding and to clarify their influence on the transient temperature field and residual stress in the lined pipe. Furthermore, the influence of the cooling time between weld overlay and girth welding and of the welding speed have been examined thermally and mechanically as they are key factors that can affect the quality of lined pipe welding.

Study of issues in difficult-to-weld thick materials by hybrid laser arc welding

NASA Astrophysics Data System (ADS)

Mazar Atabaki, Mehdi

There is a high interest for the high strength-to-weight ratio with good ductility for the welds of advanced alloys. The concern about the welding of thick materials (Advanced high strength steels (AHSS) and 5xxx and 6xxx series of aluminum alloys) has stimulated the development of manufacturing processes to overcome the associated issues. The need to weld the dissimilar materials (AHSS and aluminum alloys) is also required for some specific applications in different industries. Hence, the requirement in the development of a state-of-the-art welding procedure can be helpful to fulfill the constraints. Among the welding methods hybrid laser/arc welding (HLAW) has shown to be an effective method to join thick and difficult-to-weld materials. This process benefits from both advantages of the gas metal arc welding (GMAW) and laser welding processes. The interaction of the arc and laser can help to have enough penetration of weld in thick plates. However, as the welding of dissimilar aluminum alloys and steels is very difficult because of the formation of brittle intermetallics the present work proposed a procedure to effectively join the alloys. The reports showed that the explosively welded aluminum alloys to steels have the highest toughness, and that could be used as an "insert" (TRICLAD) for welding the thick plates of AHSS to aluminum alloys. Therefore, the HLAW of the TRICLAD-Flange side (Aluminum alloy (AA 5456)) to the Web side (Aluminum alloys (AA 6061 and AA 5456)) and the TRICLAD-Flange side (ASTM A516) to the Web side (AHSS) was studied in the present work. However, there are many issues related to HLAW of the dissimilar steels as well as dissimilar aluminum alloys that have to be resolved in order to obtain sound welds. To address the challenges, the most recent welding methods for joining aluminum alloys to steels were studied and the microstructural development, mechanical properties, and on-line monitoring of the welding processes were discussed as well

Real weld geometry determining mechanical properties of high power laser welded medium plates

NASA Astrophysics Data System (ADS)

Liu, Sang; Mi, Gaoyang; Yan, Fei; Wang, Chunming; Li, Peigen

2018-06-01

Weld width is commonly used as one of main factors to assess joint performances in laser welding. However, it changes significantly through the thickness direction in conditions of medium or thick plates. In this study, high-power autogenous laser welding was conducted on 7 mm thickness 201 stainless steel to elucidate the factor of whole weld transverse shape critically affecting the mechanical properties with the aim of predicting the performance visually through the weld appearance. The results show that single variation of welding parameters could result in great changes of weld pool figures and subsequently weld transverse shapes. All the obtained welds are composed of austenite containing small amount of cellular dendritic δ-Ferrite. The 0.2% proof stresses of Nail- and Peanut-shaped joint reach 458 MPa and 454 MPa, 88.2% and 87.5% of the base material respectively, while that of Wedge-shaped joint only comes to 371 MPa, 71.5% of the base material. The deterioration effect is believed to be caused by the axial grain zone in the weld center. The fatigue strength of joint P is a bit lower than N, but much better than W. Significant deformation incompatibility through the whole thickness and microstructure resistance to crack initiation should be responsible for the poor performance of W-shaped joints.

Dual wire weld feed proportioner

NASA Technical Reports Server (NTRS)

Nugent, R. E.

1968-01-01

Dual feed mechanism enables proportioning of two different weld feed wires during automated TIG welding to produce a weld alloy deposit of the desired composition. The wires are fed into the weld simultaneously. The relative feed rates of the wires and the wire diameters determine the weld deposit composition.

Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits II: Local welding

NASA Astrophysics Data System (ADS)

Carey, R. J.; Houghton, B. F.; Thordarson, T.

2008-03-01

As an alternative to classical welding models of fall deposits due to the progressive accumulation of hot tephra which then weld, we describe here welded deposits on the northern 1875 caldera rim of Askja volcano that have welded due to the influence of hot, discrete spatter bombs impacting into and supplying heat to a halo of surrounding tephra. This style of welding we term 'local welding' in contrast to 'regional welding' which is described elsewhere [Carey, R.J., Houghton, B.F., Thordarson, T., 2008. Contrasting styles of welding observed in the proximal Askja 1875 eruption deposits I: Regional welding. J. Volcanol. Geotherm. Res. 171, 1-19. doi:10.1016/j.jvolgeores.2007.11.020]. Locally welded deposits are associated with the rhyolitic Plinian phase of the 1875 eruption of Askja volcano. Two distinct welding units (W1 and W2) are interbedded with Plinian fall on the northern caldera rim, and grade outwards to weakly dispersed non-welded fall. Spatter bombs are found in both welding units but vary in their characteristic sizes and internal features. In the W1 unit simple bombs with homogeneous internal characteristics up to ˜ 60 cm in diameter are found. In the W2 unit, large discrete spatter bombs with complex internal features range up to 9 m in diameter. We describe here two case studies showing the effects of a) single small spatter bombs; b) multiple small spatter bombs and c) large discrete spatter bombs varying in size. Vertical and lateral profiles through welding zones reveal that the primary controls on local welding are the availability of supplied or added heat and the loading capacity of the spatter bomb. Local welding grades are much higher than that of regional welding, as the combined effects of heat, compaction and insulation can provide suitable conditions which lead to dense welding and, proximal to the spatter bomb, rheomorphic flowage. If heating and loading exceed the critical requirement for welding, porosity loss via matrix welding and

Weld defect identification in friction stir welding using power spectral density

NASA Astrophysics Data System (ADS)

Das, Bipul; Pal, Sukhomay; Bag, Swarup

2018-04-01

Power spectral density estimates are powerful in extraction of useful information retained in signal. In the current research work classical periodogram and Welch periodogram algorithms are used for the estimation of power spectral density for vertical force signal and transverse force signal acquired during friction stir welding process. The estimated spectral densities reveal notable insight in identification of defects in friction stir welded samples. It was observed that higher spectral density against each process signals is a key indication in identifying the presence of possible internal defects in the welded samples. The developed methodology can offer preliminary information regarding presence of internal defects in friction stir welded samples can be best accepted as first level of safeguard in monitoring the friction stir welding process.

Instructional Guidelines. Welding.

ERIC Educational Resources Information Center

Fordyce, H. L.; Doshier, Dale

Using the standards of the American Welding Society and the American Society of Mechanical Engineers, this welding instructional guidelines manual presents a course of study in accordance with the current practices in industry. Intended for use in welding programs now practiced within the Federal Prison System, the phases of the program are…

Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints

NASA Astrophysics Data System (ADS)

Srinivasa Rao, P.; Ramachandran, Pragash; Jebaraj, S.

2016-02-01

During the process of Gas Metal Arc (GMAW) welding, the weld joints mechanical properties are influenced by the welding parameters such as welding current and arc voltage. These parameters directly will influence the quality of the weld in terms of mechanical properties. Even small variation in any of the cited parameters may have an important effect on depth of penetration and on joint strength. In this study, S45C Constructional Steel is taken as the base metal to be tested using the parameters wire feed rate, voltage and type of shielding gas. Physical properties considered in the present study are tensile strength and hardness. The testing of weld specimen is carried out as per ASTM Standards. Mathematical models to predict the tensile strength and depth of penetration of weld joint have been developed by regression analysis using the experimental results.

Welding quality evaluation of resistance spot welding using the time-varying inductive reactance signal

NASA Astrophysics Data System (ADS)

Zhang, Hongjie; Hou, Yanyan; Yang, Tao; Zhang, Qian; Zhao, Jian

2018-05-01

In the spot welding process, a high alternating current is applied, resulting in a time-varying electromagnetic field surrounding the welder. When measuring the welding voltage signal, the impedance of the measuring circuit consists of two parts: dynamic resistance relating to weld nugget nucleation event and inductive reactance caused by mutual inductance. The aim of this study is to develop a method to acquire the dynamic reactance signal and to discuss the possibility of using this signal to evaluate the weld quality. For this purpose, a series of experiments were carried out. The reactance signals under different welding conditions were compared and the results showed that the morphological feature of the reactance signal was closely related to the welding current and it was also significantly influenced by some abnormal welding conditions. Some features were extracted from the reactance signal and combined to construct weld nugget strength and diameter prediction models based on the radial basis function (RBF) neural network. In addition, several features were also used to monitor the expulsion in the welding process by using Fisher linear discriminant analysis. The results indicated that using the dynamic reactance signal to evaluate weld quality is possible and feasible.

Properties of the welded joints of manganese steel made by low-frequency pulsed arc welding

NASA Astrophysics Data System (ADS)

Saraev, Yu. N.; Bezborodov, V. P.; Gladovskii, S. V.; Golikov, N. I.

2017-04-01

The structure, the mechanical properties, the impact toughness, and the fracture mechanisms of the welded joints made of steel 09G2S plates by direct current welding and pulsed arc welding with a modulated arc current in the frequency range 0.25-5.0 Hz are studied. The application of low-frequency pulsed arc welding allowed us to form welded joints with a fine-grained structure in the weld metal and the heat-affected zone and to achieve a higher impact toughness and a longer cyclic fatigue life as compared to the welded joints fabricated by direct current welding. The achieved effect manifests itself over the entire testing range from 20 to-60°C.

Portable Weld Tester.

ERIC Educational Resources Information Center

Eckert, Douglas

This training manual, which was developed for employees of an automotive plant, is designed to teach trainees to operate a portable weld tester (Miyachi MM-315). In chapter 1, the weld tester's components are illustrated and described, and the procedure for charging its batteries is explained. Chapter 2 illustrates the weld tester's parts,…

Welding Course Curriculum.

ERIC Educational Resources Information Center

Genits, Joseph C.

This guide is intended for use in helping students gain a fundamental background on the major aspects of the welding trade. The course emphasis is on mastery of the manipulative skills necessary to develop successful welding techniques and on acquisition of an understanding of the specialized tools and equipment used in welding. The first part…

On post-weld heat treatment cracking in tig welded superalloy ATI 718Plus

NASA Astrophysics Data System (ADS)

Asala, G.; Ojo, O. A.

The susceptibility of heat affected zone (HAZ) to cracking in Tungsten Inert Gas (TIG) welded Allvac 718Plus superalloy during post-weld heat treatment (PWHT) was studied. Contrary to the previously reported case of low heat input electron beam welded Allvac 718Plus, where HAZ cracking occurred during PWHT, the TIG welded alloy is crack-free after PWHT, notwithstanding the presence of similar micro-constituents that caused cracking in the low input weld. Accordingly, the formation of brittle HAZ intergranular micro-constituents may not be a sufficient factor to determine cracking propensity, the extent of heat input during welding may be another major factor that influences HAZ cracking during PWHT of the aerospace superalloy Allvac 718Plus.

Structure and phase composition of welded joints modified by different welding techniques

NASA Astrophysics Data System (ADS)

Smirnov, Aleksander; Popova, Natalya; Nikonenko, Elena; Ozhiganov, Eugeniy; Ababkov, Nikolay; Koneva, Nina

2017-12-01

The paper presents the results of transmission electron microscopy (TEM) during the study of structure and phase composition of heat-affected zone (HAZ) of welded joints modified via four welding techniques, namely: electrode welding and electropercussive welding both with and without artificial flaws. The artificial flows represent aluminum pieces. TEM studies are carried out within the heat-affected zone, i.e. between the deposited and base metal, at 0.5 mm distance to the former. The 0.09C-2Mn-1Si-Fe steel type is used for welding. It is shown how the type of welding affects steel morphology, phase composition, defect structure and its parameters. The type of carbide phase is detected as well as the shape and location of particles. Volume fractions are estimated for the structural steel components, alongside with such parameters as the size of α-phase fragments, scalar and excess dislocation densities, and bending-torsion amplitude of the crystal lattice. Based on these results, we determine the welding technique and the structural component thus launching a mechanism of microcrack nucleation.

Weld radiograph enigmas

NASA Technical Reports Server (NTRS)

Jemian, Wartan A.

1986-01-01

Weld radiograph enigmas are features observed on X-ray radiographs of welds. Some of these features resemble indications of weld defects, although their origin is different. Since they are not understood, they are a source of concern. There is a need to identify their causes and especially to measure their effect on weld mechanical properties. A method is proposed whereby the enigmas can be evaluated and rated, in relation to the full spectrum of weld radiograph indications. Thie method involves a signature and a magnitude that can be used as a quantitive parameter. The signature is generated as the diference between the microdensitometer trace across the radiograph and the computed film intensity derived from a thickness scan along the corresponding region of the sample. The magnitude is the measured difference in intensity between the peak and base line values of the signature. The procedure is demonstated by comparing traces across radiographs of a weld sample before and after the introduction of a hole and by a system based on a MacIntosh mouse used for surface profiling.

Automatic Welding System

NASA Astrophysics Data System (ADS)

1982-01-01

Robotic welding has been of interest to industrial firms because it offers higher productivity at lower cost than manual welding. There are some systems with automated arc guidance available, but they have disadvantages, such as limitations on types of materials or types of seams that can be welded; susceptibility to stray electrical signals; restricted field of view; or tendency to contaminate the weld seam. Wanting to overcome these disadvantages, Marshall Space Flight Center, aided by Hayes International Corporation, developed system that uses closed-circuit TV signals for automatic guidance of the welding torch. NASA granted license to Combined Technologies, Inc. for commercial application of the technology. They developed a refined and improved arc guidance system. CTI in turn, licensed the Merrick Corporation, also of Nashville, for marketing and manufacturing of the new system, called the CT2 Optical Trucker. CT2 is a non-contracting system that offers adaptability to broader range of welding jobs and provides greater reliability in high speed operation. It is extremely accurate and can travel at high speed of up to 150 inches per minute.

Laser weld jig. [Patent application

DOEpatents

Van Blarigan, P.; Haupt, D.L.

1980-12-05

A system is provided for welding a workpiece along a predetermined weld line that may be of irregular shape, which includes the step of forming a lip on the workpiece to extend parallel to the weld line, and moving the workpiece by engaging the lip between a pair of rotatable members. Rotation of one of the members at a constant speed, causes the workpiece to move so that all points on the weld line sequentially pass a fixed point in space at a constant speed, so that a laser welding beam can be directed at that fixed point to form a weld along the weld line. The workpiece can include a reusable jig forming the lip, and with the jig constructed to detachably hold parts to be welded at a position wherein the weld line of the parts extends parallel to the lip on the jig.

Welding, Bonding and Fastening, 1984

NASA Technical Reports Server (NTRS)

Buckley, J. D. (Editor); Stein, B. A. (Editor)

1985-01-01

A compilation of papers presented in a joint NASA, American Society for Metals, The George Washington University, American Welding Soceity, and Society of Manufacturing Engineers conference on Welding, Bonding, and Fastening at Langley Research Center, Hampton, VA, on October 23 to 25, 1984 is given. Papers were presented on technology developed in current research programs relevant to welding, bonding, and fastening of structural materials required in fabricating structures and mechanical systems used in the aerospace, hydrospace, and automotive industries. Topics covered in the conference included equipment, hardware and materials used when welding, brazing, and soldering, mechanical fastening, explosive welding, use of unique selected joining techniques, adhesives bonding, and nondestructive evaluation. A concept of the factory of the future was presented, followed by advanced welding techniques, automated equipment for welding, welding in a cryogenic atmosphere, blind fastening, stress corrosion resistant fasteners, fastening equipment, explosive welding of different configurations and materials, solid-state bonding, electron beam welding, new adhesives, effects of cryogenics on adhesives, and new techniques and equipment for adhesive bonding.

Modern Methods of Rail Welding

NASA Astrophysics Data System (ADS)

Kozyrev, Nikolay A.; Kozyreva, Olga A.; Usoltsev, Aleksander A.; Kryukov, Roman E.; Shevchenko, Roman A.

2017-10-01

Existing methods of rail welding, which are enable to get continuous welded rail track, are observed in this article. Analysis of existing welding methods allows considering an issue of continuous rail track in detail. Metallurgical and welding technologies of rail welding and also process technologies reducing aftereffects of temperature exposure are important factors determining the quality and reliability of the continuous rail track. Analysis of the existing methods of rail welding enable to find the research line for solving this problem.

Optimization of process parameters in welding of dissimilar steels using robot TIG welding

NASA Astrophysics Data System (ADS)

Navaneeswar Reddy, G.; VenkataRamana, M.

2018-03-01

Robot TIG welding is a modern technique used for joining two work pieces with high precision. Design of Experiments is used to conduct experiments by varying weld parameters like current, wire feed and travelling speed. The welding parameters play important role in joining of dissimilar stainless steel SS 304L and SS430. In this work, influences of welding parameter on Robot TIG Welded specimens are investigated using Response Surface Methodology. The Micro Vickers hardness tests of the weldments are measured. The process parameters are optimized to maximize the hardness of the weldments.

Influence of shielding gas pressure on welding characteristics in CO2 laser-MIG hybrid welding process

NASA Astrophysics Data System (ADS)

Chen, Yanbin; Lei, Zhenglong; Li, Liqun; Wu, Lin

2006-01-01

The droplet transfer behavior and weld characteristics have been investigated under different pressures of shielding gas in CO2 laser and metal inert/active gas (laser-MIG) hybrid welding process. The experimental results indicate that the inherent droplet transfer frequency and stable welding range of conventional MIG arc are changed due to the interaction between CO2 laser beam and MIG arc in laser-MIG hybrid welding process, and the shielding gas pressure has a crucial effect on welding characteristics. When the pressure of shielding gas is low in comparison with MIG welding, the frequency of droplet transfer decreases, and the droplet transfer becomes unstable in laser-MIG hybrid welding. So the penetration depth decreases, which shows the characteristic of unstable hybrid welding. However, when the pressure of shielding gas increases to a critical value, the hybrid welding characteristic is changed from unstable hybrid welding to stable hybrid welding, and the frequency of droplet transfer and the penetration depth increase significantly.

Welding of hermetic connectors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hieber, D.E.

1976-08-01

Certain systems use hermetically-sealed multipin connectors welded into a stainless steel support ring. Failure of these hermetic seals during welding continues to be a problem, and similar problems are anticipated on advanced systems. Since the assembly is expensive, and the detection, prevention, and repair of hermetic seal failures is costly, development of an improved welding process is important. Extended service life also requires a lower system leak rate, thus causing an increased need for maintaining the hermetic seal without supplemental epoxy sealing and repair. Experience shows that up to 70 percent of the 10-pin SA1810-2 connectors have gross leaks (greatermore » than 0.003 mm/sup 3//s Standard Temperature and Pressure (STP)) after being welded using established welding processes and without using the epoxy pre-seal process. Acceptable leak rates of less than 0.00001 mm/sup 3//s STP were achieved from 20 SA1810-2 10-pin connectors using heat sinks and an intermittent gas-tungsten-arc (GTA) weld technique. The process developed consists of using a massive copper heat sink with silicon thermal joint compound to maintain control of temperature in the hermetic seal area and using a 12-segment GTA weld with compressed argon gas cooling between weld segments. The process and techniques developed are considered acceptable for welding the SA1810 family of connectors.« less

Effect of post weld impact treatment (PWIT) on mechanical properties of spot-welded joint

NASA Astrophysics Data System (ADS)

Ghazali, F. A.; Salleh, Z.; Hyie, K. M.; Rozlin, N. M. Nik; Hamidi, S. H. Ahmad; Padzi, M. M.

2017-12-01

This paper focuses on the study of improvement for spot welding on the tensile shear and hardness by applying post weld impact treatment (PWIT) on the welded joint. The main objective of the research is to characterize and improve the mechanical properties of the joint. The method of PWIT used on the welded joint was Pneumatic Impact Treatment (PIT). The concept of PIT on spot welding is that it improves the mechanical properties of the welded zone. The working sample was undergoing a resistance spot welding of joining two similar in dimension and material of a steel plate before treated. The dimension of both plate are 110 mm × 45 mm × 1.2 mm and the material used were low carbon steel (LCS). All the welded samples were tested for its mechanical properties by performing the tensile-shear and hardness test. Tensile-shear test was conducted on the spot welded, both treated and as-welded samples using crosshead speed of 2 mm/min, while hardness test was performed using 1kgf load via Vickers hardness indenter. The effects of PIT on tensile-shear properties and hardness were evaluated and found that the implementation of PIT has increased tensile shear and hardness significantly.

Acoustic-Emission Weld-Penetration Monitor

NASA Technical Reports Server (NTRS)

Maram, J.; Collins, J.

1986-01-01

Weld penetration monitored by detection of high-frequency acoustic emissions produced by advancing weld pool as it melts and solidifies in workpiece. Acoustic emission from TIG butt weld measured with 300-kHz resonant transducer. Rise in emission level coincides with cessation of weld penetration due to sudden reduction in welding current. Such monitoring applied to control of automated and robotic welders.

Concurrent ultrasonic weld evaluation system

DOEpatents

Hood, Donald W.; Johnson, John A.; Smartt, Herschel B.

1987-01-01

A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

Concurrent ultrasonic weld evaluation system

DOEpatents

Hood, D.W.; Johnson, J.A.; Smartt, H.B.

1985-09-04

A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws.

Predicting laser weld reliability with stochastic reduced-order models. Predicting laser weld reliability

DOE PAGES

Emery, John M.; Field, Richard V.; Foulk, James W.; ...

2015-05-26

Laser welds are prevalent in complex engineering systems and they frequently govern failure. The weld process often results in partial penetration of the base metals, leaving sharp crack-like features with a high degree of variability in the geometry and material properties of the welded structure. Furthermore, accurate finite element predictions of the structural reliability of components containing laser welds requires the analysis of a large number of finite element meshes with very fine spatial resolution, where each mesh has different geometry and/or material properties in the welded region to address variability. We found that traditional modeling approaches could not bemore » efficiently employed. Consequently, a method is presented for constructing a surrogate model, based on stochastic reduced-order models, and is proposed to represent the laser welds within the component. Here, the uncertainty in weld microstructure and geometry is captured by calibrating plasticity parameters to experimental observations of necking as, because of the ductility of the welds, necking – and thus peak load – plays the pivotal role in structural failure. The proposed method is exercised for a simplified verification problem and compared with the traditional Monte Carlo simulation with rather remarkable results.« less

Analysis of the Corrosion Behavior of an A-TIG Welded SS 409 Weld Fusion Zone

NASA Astrophysics Data System (ADS)

Vidyarthy, R. S.; Dwivedi, D. K.

2017-11-01

AISI 409 (SS 409) ferritic stainless steel is generally used as the thick gauge section in freight train wagons, in ocean containers, and in sugar refinery equipment. Activating the flux tungsten inert gas (A-TIG) welding process can reduce the welding cost during fabrication of thick sections. However, corrosion behavior of the A-TIG weld fusion zone is a prime concern for this type of steel. In the present work, the effect of the A-TIG welding process parameters on the corrosion behavior of a weld fusion zone made of 8-mm-thick AISI 409 ferritic stainless-steel plate has been analyzed. Potentiodynamic polarization tests were performed to evaluate the corrosion behavior. The maximum corrosion potential ( E corr) was shown by the weld made using a welding current of 215 A, a welding speed of 95 mm/min, and a flux coating density of 0.81 mg/cm2. The minimum E corr was observed in the weld made using a welding current of 190 A, a welding speed of 120 mm/min, and a flux coating density of 1.40 mg/cm2. The current study also presents the inclusive microstructure-corrosion property relationships using the collective techniques of scanning electron microscopy, energy-dispersive x-ray spectroscopy, and x-ray diffraction.

Microstructures and electrochemical behaviors of the friction stir welding dissimilar weld.

PubMed

Shen, Changbin; Zhang, Jiayan; Ge, Jiping

2011-06-01

By using optical microscope, the microstructures of 5083/6082 friction stir welding (FSW) weld and parent materials were analyzed. Meanwhile, at ambient temperature and in 0.2 mol/L NaHS03 and 0.6 mol/L NaCl solutionby gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation, the electrochemical behavior of 5083/6082 friction stir welding weld and parent materials were comparatively investigated by gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation. The results indicated that at given processing parameters, the anti-corrosion property of the dissimilar weld was superior to those of the 5083 and 6082 parent materials. Copyright © 2011 The Research Centre for Eco-Environmental Sciences, Chinese Academy of Sciences. Published by Elsevier B.V. All rights reserved.

Infrared Thermography For Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.; Lucky, Brian D.; Spiegel, Lyle B.; Hudyma, Russell M.

1992-01-01

Infrared imaging and image-data-processing system shows temperatures of joint during welding and provides data from which rates of heating and cooling determined. Information used to control welding parameters to ensure reliable joints, in materials which microstructures and associated metallurgical and mechanical properties depend strongly on rates of heating and cooling. Applicable to variety of processes, including tungsten/inert-gas welding; plasma, laser, and resistance welding; cutting; and brazing.

Properties of welded joints in laser welding of aeronautic aluminum-lithium alloys

NASA Astrophysics Data System (ADS)

Malikov, A. G.; Orishich, A. M.

2017-01-01

The work presents the experimental investigation of the laser welding of the aluminum-lithium alloys (system Al-Mg-Li) and aluminum alloy (system Al-Cu-Li) doped with Sc. The influence of the nano-structuring of the surface layer welded joint by the cold plastic deformation method on the strength properties of the welded joint is determined. It is founded that, regarding the deformation degree over the thickness, the varying value of the welded joint strength is different for these aluminum alloys.

Concurrent ultrasonic weld evaluation system

DOEpatents

Hood, D.W.; Johnson, J.A.; Smartt, H.B.

1987-12-15

A system for concurrent, non-destructive evaluation of partially completed welds for use in conjunction with an automated welder is disclosed. The system utilizes real time, automated ultrasonic inspection of a welding operation as the welds are being made by providing a transducer which follows a short distance behind the welding head. Reflected ultrasonic signals are analyzed utilizing computer based digital pattern recognition techniques to discriminate between good and flawed welds on a pass by pass basis. The system also distinguishes between types of weld flaws. 5 figs.

Automation of the electron-beam welding process

NASA Astrophysics Data System (ADS)

Koleva, E.; Dzharov, V.; Kardjiev, M.; Mladenov, G.

2016-03-01

In this work, the automatic control is considered of the vacuum and cooling systems of the located in the IE-BAS equipment for electron-beam welding, evaporation and surface modification. A project was elaborated for the control and management based on the development of an engineering support system using existing and additional technical means of automation. Optimization of the indicators, which are critical for the duration of reaching the working regime and stopping the operation of the installation, can be made using experimentally obtained transient characteristics. The automation of the available equipment aimed at improving its efficiency and the repeatability of the obtained results, as well as at stabilizing the process parameters, should be integrated in an Engineering Support System which, besides the operator supervision, consists of several subsystems for equipment control, data acquisition, information analysis, system management and decision-making support.

Tailor-welded blanks and their production

NASA Astrophysics Data System (ADS)

Yan, Qi

2005-01-01

Tailor welded blanks had been widely used in the automobile industry. A tailor welded blank consists of several flat sheets that were laser welded together before stamping. A combination of different materials, thickness, and coatings could be welded together to form a blank for stamping car body panels. As for the material for automobile industry, this technology was one of the development trend for automobile industry because of its weight reduction, safety improvement and economical use of materials. In this paper, the characters and production of tailor welded blanks in the market were discussed in detail. There had two major methods to produce tailor welded blanks. Laser welding would replace mesh seam welding for the production of tailor welded blanks in the future. The requirements on the edge preparation of unwelded blanks for tailor welded blanks were higher than the other steel processing technology. In order to produce the laser welded blank, there had the other process before the laser welding in the factory. In the world, there had three kinds of patterns for the large volume production of tailor welded blanks. In China, steel factory played the important role in the promotion of the application of tailor welded blanks. The competition for the supply of tailor welded blanks to the automobile industry would become fierce in the near future. As a result, the demand for the quality control on the production of tailor welded blanks would be the first priority concern for the factory.

The Effect of Welding Energy on the Microstructural and Mechanical Properties of Ultrasonic-Welded Copper Joints

PubMed Central

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-01-01

The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed. PMID:28772553

Evaluation of Residual Stress Measurements Before and After Post-Weld Heat Treatment in the Weld Repairs

NASA Astrophysics Data System (ADS)

Pardowska, Anna M.; Price, John W. H.; Finlayson, Trevor R.; Ibrahim, R.

2010-11-01

Welding repairs are increasingly a structural integrity concern for aging pressure vessel and piping components. It has been demonstrated that the residual stress distribution near repair welds can be drastically different from that of the original weld. Residual stresses have a significant effect on the lifetime performance of a weld, and a reduction of these stresses is normally desirable. The aim of this paper is to investigate residual stresses in various weld repair arrangements using the non-destructive neutron diffraction technique. This research is focused on characterization of the residual stress distribution: (i) in the original weld; (ii) in a shallow toe weld repair; and (iii) after conventional post-weld heat treatment. The focus of the measurements is on the values of the subsurface strain/stress variations across the weld.

The Effect of Welding Energy on the Microstructural and Mechanical Properties of Ultrasonic-Welded Copper Joints.

PubMed

Yang, Jingwei; Cao, Biao; Lu, Qinghua

2017-02-16

The effects of welding energy on the mechanical and microstructural characteristics of ultrasonic-welded pure copper plates were investigated. Complex dynamic recrystallization and grain growth occurred inside the weld zone during ultrasonic welding. At a low welding energy, a thin band of straight weld interfaces was observed and had an ultra-fine grain structure. With an increase in welding energy, the weld interface progressively changed from flat to sinusoidal, and eventually turned into a convoluted wavy pattern, bearing similarities to shear instabilities, as observed in fluid dynamics. The lap shear load of the joints initially increased and then remained stable as the welding energy increased. The tensile characteristics of the joints significantly depended on the development of plastic deformation at the interface. The influence of the microstructure on the hardness was also discussed.

Influence of the welding temperature and the welding speed on the mechanical properties of friction stir welds in EN AW-2219-T87

NASA Astrophysics Data System (ADS)

Bachmann, A.; Krutzlinger, M.; Zaeh, M. F.

2018-06-01

Friction Stir Welding (FSW) is an innovative joining technique, which has proven to produce high quality joints in high strength aluminum alloys. Consequently, it is commonly used to manufacture lightweight aerospace structures with stringent requirements. For these structures, it is necessary to ensure a high ultimate tensile strength (UTS). Various studies have reported that the UTS is significantly influenced by the welding parameters. Samples welded with different parameter sets showed a considerably different UTS, despite being free from detectable welding defects (e.g. tunnel defect, voids, or lack of penetration). Based on the observations in the literature, a hypothesis was posed. The welding temperature along with the welding speed determine the UTS of the weld. This study aims to prove this hypothesis experimentally by using temperature-controlled FSW to join plates of EN AW-2219-T87 in butt joint configuration. The welded samples were examined using visual inspection, metallography, X-ray imaging, and uniaxial tensile tests. Finally, a statistical analysis was conducted. Hereby, the hypothesis was confirmed.

U-Groove Aluminum Weld Strength Improvement

NASA Technical Reports Server (NTRS)

Verderaime, V.; Vaughan, R.

1997-01-01

Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. One is the source of peaking in which the extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe angular distortion that induces bending under uniaxial loading. The other is the filler strain hardening decreasing with increasing filler pass sequences, producing the weakest welds on the last weld pass side. Both phenomena are governed by weld pass sequences. Many industrial welding schedules unknowingly compound these effects, which reduce the weld strength. A depeaking index model was developed to select filler pass thickness, pass numbers, and sequences to improve depeaking in the welding process. The result was to select the number and sequence of weld passes to reverse the peaking angle such as to combine the strongest weld pass side with the peaking induced bending tension component side to provide a more uniform stress and stronger weld under axial tensile loading.

Plasma Processes of Cutting and Welding

DTIC Science & Technology

1976-02-01

TIG process. 2.2.2 Keyhole Welding In plasma arc welding , the term...Cutting 3 3 4 4 4 2.2 Plasma Arc Welding 5 2.2.1 Needle Arc Welding 2.2.2 Keyhole Welding 5 6 3. Applications 8 93.1 Economics 4. Environmental Aspects of...Arc Lengths III. Needle Arc Welding Conditions IV. Keyhole Welding Conditions v. Chemical Analyses of Plates Used - vii - 1. 2. 3. 4. 5. 6. 7. 8.

Enhanced diffusion welding

NASA Technical Reports Server (NTRS)

Holko, K. H.; Moore, T. J. (Inventor)

1973-01-01

Surfaces of unrecrystallized alloys are sanded and polished. This is followed by a two-step welding process by which the strength of the parent metal is retained at the weld joint. The first step forces the surfaces into intimate contact at a temperature where the metal still has good ductility. The second step causes diffusion, recrystallization, and grain growth across the original weld interface.

Effect of rotation speed and welding speed on Friction Stir Welding of AA1100 Aluminium alloy

NASA Astrophysics Data System (ADS)

Raja, P.; Bojanampati, S.; Karthikeyan, R.; Ganithi, R.

2018-04-01

Aluminum AA1100 is the most widely used grade of Aluminium due to its excellent corrosion resistance, high ductility and reflective finish, the selected material was welded with Friction Stir Welding (FSW) process on a CNC machine, using a combination of different tool rotation speed (1500 rpm, 2500 rpm, 3500 rpm) and welding speed (10 mm/min, 30 mm/min, 50 mm/min) as welding parameters. The effect of FSW using this welding parameter was studied by measuring the ultimate tensile strength of the welded joints. A high-speed steel tool was prepared for welding the Aluminium AA1100 alloy having an 8mm shoulder diameter and pin dimension of 4mm diameter and 2.8 mm length. The welded joints were tested using the universal testing machine. It was found that Ultimate Tensile Strength of FSW specimen was highest with a value of 98.08 MPa when the weld was performed at rotation speed of 1500 RPM and welding speed of 50 mm/min.

Effects of Flux Precoating and Process Parameter on Welding Performance of Inconel 718 Alloy TIG Welds

NASA Astrophysics Data System (ADS)

Lin, Hsuan-Liang; Wu, Tong-Min; Cheng, Ching-Min

2014-01-01

The purpose of this study is to investigate the effect of activating flux on the depth-to-width ratio (DWR) and hot cracking susceptibility of Inconel 718 alloy tungsten inert gas (TIG) welds. The Taguchi method is employed to investigate the welding parameters that affect the DWR of weld bead and to achieve optimal conditions in the TIG welds that are coated with activating flux in TIG (A-TIG) process. There are eight single-component fluxes used in the initial experiment to evaluate the penetration capability of A-TIG welds. The experimental results show that the Inconel 718 alloy welds precoated with 50% SiO2 and 50% MoO3 flux were provided with better welding performance such as DWR and hot cracking susceptibility. The experimental procedure of TIG welding process using mixed-component flux and optimal conditions not only produces a significant increase in DWR of weld bead, but also decreases the hot cracking susceptibility of Inconel 718 alloy welds.

Effect of Pulse Parameters on Weld Quality in Pulsed Gas Metal Arc Welding: A Review

NASA Astrophysics Data System (ADS)

Pal, Kamal; Pal, Surjya K.

2011-08-01

The weld quality comprises bead geometry and its microstructure, which influence the mechanical properties of the weld. The coarse-grained weld microstructure, higher heat-affected zone, and lower penetration together with higher reinforcement reduce the weld service life in continuous mode gas metal arc welding (GMAW). Pulsed GMAW (P-GMAW) is an alternative method providing a better way for overcoming these afore mentioned problems. It uses a higher peak current to allow one molten droplet per pulse, and a lower background current to maintain the arc stability. Current pulsing refines the grains in weld fusion zone with increasing depth of penetration due to arc oscillations. Optimum weld joint characteristics can be achieved by controlling the pulse parameters. The process is versatile and easily automated. This brief review illustrates the effect of pulse parameters on weld quality.

Sensors control gas metal arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Siewert, T.A.; Madigan, R.B.; Quinn, T.P.

1997-04-01

The response time of a trained welder from the time a weld problem is identified to the time action is taken is about one second--especially after a long, uneventful period of welding. This is acceptable for manual welding because it is close to the time it takes for the weld pool to solidify. If human response time were any slower, manual welding would not be possible. However, human response time is too slow to respond to some weld events, such as melting of the contact tube in gas metal arc welding (GMAW), and only automated intelligent control systems can reactmore » fast enough to correct or avoid these problems. Control systems incorporate welding knowledge that enables intelligent decisions to be made about weld quality and, ultimately, to keep welding parameters in the range where only high-quality welds are produced. This article discusses the correlation of electrical signals with contact-tube wear, changes in shielding gas, changes in arc length, and other weld process data.« less

Control of Gas Tungsten Arc welding pool shape by trace element addition to the weld pool

DOEpatents

Heiple, C.R.; Burgardt, P.

1984-03-13

An improved process for Gas Tungsten Arc welding maximizes the depth/width ratio of the weld pool by adding a sufficient amount of a surface active element to insure inward fluid flow, resulting in deep, narrow welds. The process is especially useful to eliminate variable weld penetration and shape in GTA welding of steels and stainless steels, particularly by using a sulfur-doped weld wire in a cold wire feed technique.

Effects of alloying element on weld characterization of laser-arc hybrid welding of pure copper

NASA Astrophysics Data System (ADS)

Hao, Kangda; Gong, Mengcheng; Xie, Yong; Gao, Ming; Zeng, Xiaoyan

2018-06-01

Effects of alloying elements of Si and Sn on weld characterizations of laser-arc hybrid welded pure copper (Cu) with thickness of 2 mm was studied in detail by using different wires. The weld microstructure was analyzed, and the mechanical properties (micro-hardness and tensile property), conductivity and corrosion resistance were tested. The results showed that the alloying elements benefit the growth of column grains within weld fusion zone (FZ), increase the ultimate tensile strength (UTS) of the FZ and weld corrosion resistance, and decrease weld conductivity. The mechanisms were discussed according to the results.

Correlation analysis of the variation of weld seam and tensile strength in laser welding of galvanized steel

NASA Astrophysics Data System (ADS)

Sinha, Amit Kumar; Kim, Duck Young; Ceglarek, Darek

2013-10-01

Many advantages of laser welding technology such as high speed and non-contact welding make the use of the technology more attractive in the automotive industry. Many studies have been conducted to search the optimal welding condition experimentally that ensure the joining quality of laser welding that relies both on welding system configuration and welding parameter specification. Both non-destructive and destructive techniques, for example, ultrasonic inspection and tensile test are widely used in practice for estimating the joining quality. Non-destructive techniques are attractive as a rapid quality testing method despite relatively low accuracy. In this paper, we examine the relationship between the variation of weld seam and tensile shear strength in the laser welding of galvanized steel in a lap joint configuration in order to investigate the potential of the variation of weld seam as a joining quality estimator. From the experimental analysis, we identify a trend in between maximum tensile shear strength and the variation of weld seam that clearly supports the fact that laser welded parts having larger variation in the weld seam usually have lower tensile strength. The discovered relationship leads us to conclude that the variation of weld seam can be used as an indirect non-destructive testing method for estimating the tensile strength of the welded parts.

Selection of optimal welding condition for GTA pulse welding in root-pass of V-groove butt joint

NASA Astrophysics Data System (ADS)

Yun, Seok-Chul; Kim, Jae-Woong

2010-12-01

In the manufacture of high-quality welds or pipeline, a full-penetration weld has to be made along the weld joint. Therefore, root-pass welding is very important, and its conditions have to be selected carefully. In this study, an experimental method for the selection of optimal welding conditions is proposed for gas tungsten arc (GTA) pulse welding in the root pass which is done along the V-grooved butt-weld joint. This method uses response surface analysis in which the width and height of back bead are chosen as quality variables of the weld. The overall desirability function, which is the combined desirability function for the two quality variables, is used as the objective function to obtain the optimal welding conditions. In our experiments, the target values of back bead width and height are 4 mm and zero, respectively, for a V-grooved butt-weld joint of a 7-mm-thick steel plate. The optimal welding conditions could determine the back bead profile (bead width and height) as 4.012 mm and 0.02 mm. From a series of welding tests, it was revealed that a uniform and full-penetration weld bead can be obtained by adopting the optimal welding conditions determined according to the proposed method.

Automatic welding of stainless steel tubing

NASA Technical Reports Server (NTRS)

Clautice, W. E.

1978-01-01

The use of automatic welding for making girth welds in stainless steel tubing was investigated as well as the reduction in fabrication costs resulting from the elimination of radiographic inspection. Test methodology, materials, and techniques are discussed, and data sheets for individual tests are included. Process variables studied include welding amperes, revolutions per minute, and shielding gas flow. Strip chart recordings, as a definitive method of insuring weld quality, are studied. Test results, determined by both radiographic and visual inspection, are presented and indicate that once optimum welding procedures for specific sizes of tubing are established, and the welding machine operations are certified, then the automatic tube welding process produces good quality welds repeatedly, with a high degree of reliability. Revised specifications for welding tubing using the automatic process and weld visual inspection requirements at the Kennedy Space Center are enumerated.

Upgraded HFIR Fuel Element Welding System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sease, John D

2010-02-01

The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. Inmore » recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.« less

Welding in Space Workshop

NASA Technical Reports Server (NTRS)

Workman, Gary L.

1990-01-01

The potential was discussed for welding in space, its advantages and disadvantages, and what type of programs can benefit from the capability. Review of the various presentations and comments made in the course of the workshop suggests several routes to obtaining a better understanding of how welding processes can be used in NASA's initiatives in space. They are as follows: (1) development of a document identifying well processes and equipment requirements applicable to space and lunar environments; (2) more demonstrations of welding particular hardware which are to be used in the above environments, especially for space repair operations; (3) increased awareness among contractors responsible for building space equipment as to the potential for welding operations in space and on other planetary bodies; and (4) continuation of space welding research projects is important to maintain awareness within NASA that welding in space is viable and beneficial.

Indian Vacuum Society: The Indian Vacuum Society

NASA Astrophysics Data System (ADS)

Saha, T. K.

2008-03-01

The Indian Vacuum Society (IVS) was established in 1970. It has over 800 members including many from Industry and R & D Institutions spread throughout India. The society has an active chapter at Kolkata. The society was formed with the main aim to promote, encourage and develop the growth of Vacuum Science, Techniques and Applications in India. In order to achieve this aim it has conducted a number of short term courses at graduate and technician levels on vacuum science and technology on topics ranging from low vacuum to ultrahigh vacuum So far it has conducted 39 such courses at different parts of the country and imparted training to more than 1200 persons in the field. Some of these courses were in-plant training courses conducted on the premises of the establishment and designed to take care of the special needs of the establishment. IVS also regularly conducts national and international seminars and symposia on vacuum science and technology with special emphasis on some theme related to applications of vacuum. A large number of delegates from all over India take part in the deliberations of such seminars and symposia and present their work. IVS also arranges technical visits to different industries and research institutes. The society also helped in the UNESCO sponsored post-graduate level courses in vacuum science, technology and applications conducted by Mumbai University. The society has also designed a certificate and diploma course for graduate level students studying vacuum science and technology and has submitted a syllabus to the academic council of the University of Mumbai for their approval, we hope that some colleges affiliated to the university will start this course from the coming academic year. IVS extended its support in standardizing many of the vacuum instruments and played a vital role in helping to set up a Regional Testing Centre along with BARC. As part of the development of vacuum education, the society arranges the participation of

Saturn S-2 production operations techniques: Production welding. Volume 1: Bulkhead welding

NASA Technical Reports Server (NTRS)

Abel, O. G.

1970-01-01

The complex Saturn S-2 welding processes and procedures required considerable development and refinement to establish a production capability that could consistently produce aluminum alloy welds within specified requirements. The special processes and techniques are defined that were established for the welding of gore-to-gore and manhole- or closeout-to-gore.

Weld failure detection

DOEpatents

Pennell, William E.; Sutton, Jr., Harry G.

1981-01-01

Method and apparatus for detecting failure in a welded connection, particrly applicable to not readily accessible welds such as those joining components within the reactor vessel of a nuclear reactor system. A preselected tag gas is sealed within a chamber which extends through selected portions of the base metal and weld deposit. In the event of a failure, such as development of a crack extending from the chamber to an outer surface, the tag gas is released. The environment about the welded area is directed to an analyzer which, in the event of presence of the tag gas, evidences the failure. A trigger gas can be included with the tag gas to actuate the analyzer.

[The effects of different welding wires on the mechanical properties of laser welding joints].

PubMed

Huang, Qing-feng; Zhang, Jian-zhong; Jiang, Wei-dong; Li, Quan; Yu, Jin-xing

2006-08-01

To evaluate the mechanical properties and microstructure of laser-welded joints with different welding wires for clinical use of welding wire. The standard tensile test and three-point bending test rods were made from Co-Cr and Ni-Cr alloy, and were laser-welded with different welding wire (commercially welding wire and casting wire). Then the tensile rods were tested for the ultimate tensile strength (UTS), and the bending rods for the ultimate bending strength (UBS). The results was analyzed by one-way ANOVA. The tensile fracture surface were examined by scanning electron microscopy (SEM). Metallurgical analysis were also performed on polished longitudinal sectioned samples. For Co-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (606.40+/-82.53)MPa and (693.61+/-47.68)MPa; the UBS was respectively (997.95+/-88.89)MPa and (1160.76+/-91.59)MPa. ANOVA showed a significant difference of UTS and UBS between the two groups at the 0.05 level (P<0.05). For Ni-Cr alloy, the UTS of casting wire group and commercially welding wire group was respectively (558.14+/-46.75)MPa and (582.32+/-35.43)MPa; the UBS was respectively (1084.75+/-46.02)MPa and (1078.29+/-36.25)MPa. There was no significant difference between the two groups (P>0.05). SEM and metallurgical examination showed the welded zone exhibiting more cracks in the casting wire group than in the commercially welding wire group. It would be advisable to work with commercially welding wire for the joints that need better strength.

Method for welding beryllium

DOEpatents

Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

1997-01-01

A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

Method for welding beryllium

DOEpatents

Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

1997-04-01

A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

Industrial laser welding evaluation study

NASA Technical Reports Server (NTRS)

Hella, R.; Locke, E.; Ream, S.

1974-01-01

High power laser welding was evaluated for fabricating space vehicle boosters. This evaluation was made for 1/4 in. and 1/2 in. aluminum (2219) and 1/4 in. and 1/2 in. D6AC steel. The Avco HPL 10 kW industrial laser was used to perform the evaluation. The objective has been achieved through the completion of the following technical tasks: (1) parameter study to optimize welding and material parameters; (2) preparation of welded panels for MSFC evaluation; and (3) demonstration of the repeatability of laser welding equipment. In addition, the design concept for a laser welding system capable of welding large space vehicle boosters has been developed.

Welding III.

ERIC Educational Resources Information Center

Allegheny County Community Coll., Pittsburgh, PA.

Instructional objectives and performance requirements are outlined in this course guide for Welding III, an advanced course in arc welding offered at the Community College of Allegheny County to provide students with the proficiency necessary for industrial certification. The course objectives, which are outlined first, specify that students will…

A Study to Increase Weld Penetration in P91 Steel During TIG Welding by using Activating Fluxes

NASA Astrophysics Data System (ADS)

Singh, Akhilesh Kumar; Kumar, Mayank; Dey, Vidyut; Naresh Rai, Ram

2017-08-01

Activated Flux TIG (ATIG) welding is a unique joining process, invented at Paton Institute of electric welding in 1960. ATIG welding process is also known as flux zoned TIG (FZTIG). In this process, a thin layer of activating flux is applied along the line on the surface of the material where the welding is to be carries out. The ATIG process aids to increase the weld penetration in thick materials. Activating fluxes used in the literature show the use of oxides like TiO2, SiO2, Cr2O3, ZnO, CaO, Fe2O3, and MnO2 during welding of steels. In the present study, ATIG was carried out on P-91 steel. Though, Tungsten Inert Gas welding gives excellent quality welds, but the penetration obtained in such welding is still demanding. P91 steel which is ferritic steel is used in high temperature applications. As this steel is, generally, used in thick sections, fabrication of such structures with TIG welding is limited, due to its low depth of penetration. To increase the depth of penetration in P91while welding with ATIG, the role of various oxides were investigated. Apart from the oxides mentioned above, in the present study the role of B2O3, V2O5 and MgO, during ATIG welding of P91 was investigated. It was seen that, compared to TIG welding, there was phenomenal increase in weld penetration during ATIG welding. Amongst all the oxides used in this study, maximum penetration was achieved in case of B2O3. The measurements of weld penetration, bead width and heat affected zone of the weldings were carried out using an image analysis technique.

Physics of Fusion Welding

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

1986-01-01

Applicabilities and limitations of three techniques analyzed. NASA technical memorandum discusses physics of electron-beam, gas/ tungsten-arc, and laser-beam welding. From comparison of capabilities and limitations of each technique with regard to various welding conditions and materials, possible to develop criteria for selecting best welding technique in specific application. All three techniques classified as fusion welding; small volume of workpiece melted by intense heat source. Heat source moved along seam, leaving in wake solid metal that joins seam edges together.

Microstructure Formation in Dissimilar Metal Welds: Electron Beam Welding of Ti/Ni

NASA Astrophysics Data System (ADS)

Chatterjee, Subhradeep; Abinandanan, T. A.; Reddy, G. Madhusudhan; Chattopadhyay, Kamanio

2016-02-01

We present results for electron beam welding of a binary Ti/Ni dissimilar metal couple. The difference in physical properties of the base metals and metallurgical features (thermodynamics and kinetics) of the system influence both macroscopic transport and microstructure development in the weld. Microstructures near the fusion interfaces are markedly different from those inside the weld region. At the Ti side, Ti2Ni dendrites are observed to grow toward the fusion interface, while in the Ni side, layered growth of γ-Ni, Ni3Ti, and Ni3Ti + NiTi eutectic is observed. Different morphologies of the latter eutectic constitute the predominant microstructure inside the weld metal region. These results are compared and contrasted with those from laser welding of the same binary couple, and a scheme of solidification is proposed to explain the observations. This highlights notable departures from welding of similar and other dissimilar metals such as a significant asymmetry in heat transport that governs progress of solidification from each side of the couple, and a lack of unique liquidus isotherm characterizing the liquid-solid front.

49 CFR 192.225 - Welding procedures.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

49 CFR 192.225 - Welding procedures.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 49 Transportation 3 2013-10-01 2013-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

49 CFR 192.225 - Welding procedures.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 49 Transportation 3 2014-10-01 2014-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

49 CFR 192.225 - Welding procedures.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 49 Transportation 3 2012-10-01 2012-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

49 CFR 192.225 - Welding procedures.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 3 2011-10-01 2011-10-01 false Welding procedures. 192.225 Section 192.225... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.225 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures...

Influence of the Gap Width on the Geometry of the Welded Joint in Hybrid Laser-Arc Welding

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulskiy, I.; Kuznetsov, M.; Akhmetov, A.; Mildebrath, M.; Hassel, T.

The aim of this research was the experimental investigation of the influence of the gap width and speed of the welding wire on the changes of the geometry in the welded joint in the hybrid laser-arc welding of shipbuilding steel RS E36. The research was divided into three parts. First, in order to understand the influence of the gap width on the welded joint geometry, experimental research was done using continuous wave fiber laser IPG YLS-15000 with arc rectifier VDU-1500DC. The second part involved study of the geometry of the welded joint and hardness test results. Three macrosections from each welded joint were obtained. Influence of the gap width and welding wire speed on the welded joint geometry was researched in the three lines: in the right side of the plates, middle welded joint and in the root welded joint.

U-Groove aluminum weld strength improvement

NASA Technical Reports Server (NTRS)

Verderaime, V.; Vaughan, R.

1996-01-01

Though butt-welds are among the most preferred joining methods in aerostructures, their strength dependence on inelastic mechanics is generally the least understood. This study investigated experimental strain distributions across a thick aluminum U-grooved weld and identified two weld process considerations for improving the multipass weld strength. The extreme thermal expansion and contraction gradient of the fusion heat input across the groove tab thickness produces severe peaking, which induces bending under uniaxial loading. The filler strain-hardening decreased with increasing filler pass sequence, producing the weakest welds on the last pass side. Current welding schedules unknowingly compound these effects which reduce the weld strength. A depeaking index model was developed to select filler pass thicknesses, pass numbers, and sequences to improve depeaking in the welding process. The intent is to combine the strongest weld pass side with the peaking induced bending tension to provide a more uniform stress and stronger weld under axial tensile loading.

Laser Beam Welding of Nitride Steel Components

NASA Astrophysics Data System (ADS)

Gu, Hongping; Yin, Guobin; Shulkin, Boris

Laser beam welding is a joining technique that has many advantages over conventional GMAW welding, such as low heat input, short cycle time as well as good cosmetic welds. Laser beam welding has been widely used for welding powertrain components in automotive industry. When welding nitride steel components, however, laser beam welding faces a great challenge. The difficulty lies in the fact that the nitride layer in the joint releases the nitrogen into the weld pool, resulting in a porous weld. This research presents an industrial ready solution to prevent the nitrogen from forming gas bubbles in the weld.

An investigation into underwater wet welding using the flux cored arc welding process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brydon, A.M.; Nixon, J.H.

1995-12-31

For the last two years, Cranfield has been carrying out a program of process investigations into wet underwater welding (Graham and Nixon 1993, Nixon and Webb 1994), and has demonstrated that it is possible to markedly improve the stability and consistency of the process by using control techniques developed for hyperbaric welding. In the project reported below, an initial evaluation of wet flux cored arc welding was undertaken. Although there continues to be considerable resistance to the use of wet welding on structures in the North Sea, continued pressure to reduce repair and maintenance costs is causing the industry tomore » re-examine techniques previously discounted, such as wet welding (Anon 1993).« less

Diode laser welding of polypropylene: investigations of the microstructures in the welded seam

NASA Astrophysics Data System (ADS)

Abed, S.; Laurens, Patricia; Carretero, C.; Deschamps, J. R.; Duval, C.

2003-03-01

Laser welding of thermoplastic polymers is a non-contact process especially efficient for joining thermoplastic polymers. This innovative technology is already used for industrial series production in different sectors (automobile, packaging,...). The majority of the basic research concerns the weld strength depending on polymer nature, optical properties, butt design and process parameters. Nevertheless, a lack of knowledge concerning the influence of thermal history of the weld seam on morphology of semicrystalline polymer still exists, when this parameter strongly influences the strength of the weld. Actual results of diode laser transmission welding (LTW) experiments on polypropylene, a semicrystalline polymer widely used in industry, could contribute to a better understanding of the process itself and to success in practical applications.

Thermoplastic welding apparatus and method

DOEpatents

Matsen, Marc R.; Negley, Mark A.; Geren, William Preston; Miller, Robert James

2017-03-07

A thermoplastic welding apparatus includes a thermoplastic welding tool, at least one tooling surface in the thermoplastic welding tool, a magnetic induction coil in the thermoplastic welding tool and generally encircling the at least one tooling surface and at least one smart susceptor in the thermoplastic welding tool at the at least one tooling surface. The magnetic induction coil is adapted to generate a magnetic flux field oriented generally parallel to a plane of the at least one smart susceptor.

Ultrasonic Spot Welding of a Rare-Earth Containing ZEK100 Magnesium Alloy: Effect of Welding Energy

NASA Astrophysics Data System (ADS)

Macwan, A.; Chen, D. L.

2016-04-01

Ultrasonic spot welding was used to join a low rare-earth containing ZEK100 Mg alloy at different levels of welding energy, and tensile lap shear tests were conducted to evaluate the failure strength in relation to the microstructural changes. It was observed that dynamic recrystallization occurred in the nugget zone; the grain size increased and microhardness decreased with increasing welding energy arising from the increasing interface temperature and strain rate. The weld interface experienced severe plastic deformation at a high strain rate from ~500 to ~2100 s-1 with increasing welding energy from 500 to 2000 J. A relationship between grain size and Zener-Hollomon parameter, and a Hall-Petch-type relationship between microhardness and grain size were established. The tensile lap shear strength and failure energy were observed to first increase with increasing welding energy, reach the maximum values at 1500 J, and then decrease with a further increase in the welding energy. The samples welded at a welding energy ≤1500 J exhibited an interfacial failure mode, while nugget pull-out occurred in the samples welded at a welding energy above 1500 J. The fracture surfaces showed typical shear failure. Low-temperature tests at 233 K (-40 °C) showed no significant effect on the strength and failure mode of joints welded at the optimal welding energy of 1500 J. Elevated temperature tests at 453 K (180 °C) revealed a lower failure load but a higher failure energy due to the increased deformability, and showed a mixed mode of partial interfacial failure and partial nugget pull-out.

Method and apparatus for assessing weld quality

DOEpatents

Smartt, Herschel B.; Kenney, Kevin L.; Johnson, John A.; Carlson, Nancy M.; Clark, Denis E.; Taylor, Paul L.; Reutzel, Edward W.

2001-01-01

Apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

73rd American Welding Society annual meeting

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1992-01-01

The volume includes the abstracts of papers presented at the 73rd American Welding Society Annual Meeting. Detailed summaries are given for 118 technical sessions papers discussing computer and control applications in welding, stainless steel, nickel and nickel alloys, weld metal microstructure, shipbuilding, consumables, structural welding, investigations in arc welding and cutting, arc welding processes, weldability testing, piping and tubing, high energy beam welding processes, welding metallurgy of structural steels, new applications, weld metal behavior, NDT certification, aluminum welding, submerged arc welding, modeling studies, resistance welding, friction welding, and safety and health. The 23rd International AWS Brazing and Soldering Conference wasmore » also held during this meeting. The topics presented in 24 papers included recent developments in soldering technology, brazing of stainless steel, brazing of ceramics and nickel material, filler metal developments for torch brazing, and developments in diffusion and induction brazing.« less

Galvanic Corrosion Behavior of Microwave Welded and Post-weld Heat-Treated Inconel-718 Joints

NASA Astrophysics Data System (ADS)

Bansal, Amit; Sharma, Apurbba Kumar; Kumar, Pradeep

2017-05-01

In the present study, corrosion behavior of microwave welded Inconel-718 at various conditions was investigated. Welding of Inconel-718 in 980 °C solution-treated condition was performed using microwave hybrid heating technique. The microwave welds were subjected to post-heat treatment for improving its microstructure and mechanical properties by solubilizing the Nb-enriched Laves phase. The microstructural features of the fabricated welds at various conditions were investigated through scanning electron microscopy. The electrochemical testing results revealed that Inconel-718 welds were galvanic corroded when they were anodically polarized in 3.5 wt.% NaCl solution at 28 °C. The difference in the corrosion potentials between the base metal (BM) and fusion zone (FZ) in an Inconel-718 weld was the main factor for galvanic corrosion. The highest corrosion was occurred in the as-welded/aged weldments, followed by 980 °C solution-treated and aged weldments, as-welded specimen, and 1080 °C solution-treated and aged (1080STA) weldments. The least galvanic corrosion was occurred in the 1080STA specimens due to almost uniform microstructure developed in the weldment after the treatment. Thus, it was possible to minimize the galvanic corrosion in the microwave welded Inconel-718 by 1080STA treatment which resulted in reducing the difference in corrosion potentials between the BM and the FZ.

Mechanical Characteristics of Welded Joints of Aluminum Alloy 6061 T6 Formed by Arc and Friction Stir Welding

NASA Astrophysics Data System (ADS)

Astarita, A.; Squillace, A.; Nele, L.

2016-01-01

Butt welds formed by arc welding in inert gas with nonconsumable electrode (tungsten inert gas (TIG) welding) and by friction stir welding (FSW) from aluminum alloy AA6061 T6 are studied. Comparative analysis of the structures and mechanical properties of the welded joints is performed using the results of optical and electron microscopy, tensile tests, tests for residual bending ductility, and measurements of microhardness. The changes in the microstructure in different zones and the degrees of degradation of the mechanical properties after the welding are determined. It is shown that the size of the tool for the friction stir welding affects the properties of the welds. Quantitative results showing the relation between the microscopic behavior of the alloy and the welding-induced changes in the microstructure are obtained. Friction stir welding is shown to provide higher properties of the welds.

Welding Curriculum.

ERIC Educational Resources Information Center

EASTCONN Regional Educational Services Center, North Windham, CT.

The purpose of this welding program is to provide students with skills and techniques to become employed as advanced apprentice welders. The welding program manual includes the following sections: (1) course description; (2) general objectives; (3) competencies; (4) curriculum outline for 13 areas; (5) 13 references; and (6) student progress…

Method for welding chromium molybdenum steels

DOEpatents

Sikka, Vinod K.

1986-01-01

Chromium-molybdenum steels exhibit a weakening after welding in an area adjacent to the weld. This invention is an improved method for welding to eliminate the weakness by subjecting normalized steel to a partial temper prior to welding and subsequently fully tempering the welded article for optimum strength and ductility.

Tensile Properties of Friction Stir Welded Joints of AA 2024-T6 Alloy at Different Welding Speeds

NASA Astrophysics Data System (ADS)

Avula, Dhananjayulu; Devuri, Venkateswarlu; Cheepu, Muralimohan; Dwivedi, Dheerendra Kumar

2018-03-01

The influence of welding speed on the friction stir welded joint properties of hardness, tensile properties, defects and microstructure characterization are studied in the present study. The friction stir welding was conducted on AA2014-T6 heat treated alloy with 5 mm thickness plate in butt joint configuration. The welding speed was varied from 8 mm/min to 120 mm/min at the fixed travel speed and load conditions. It is observed that the welding speeds at higher rate with wide range can be possible to weld this alloy at higher rates of tool revolution suggesting that the inherent capability of friction stir welding technique for aluminum 2014 alloys. The strength of the joints gradually increases with enhancing of welding speed. The micro structural observations exhibited the formation of equiaxed grains in the stir zone and slightly in the thermo-mechanically affected zone. In addition, the size of the grains decreases with increase in welding speed owing to the presence of low heat input. Hence the hardness of the joints slightly increased in the stir zones over the other zones of the weld nugget. The joint strength initially increases with the welding speed and starts to decreases after reaching to the maximum value. The relationship between the welding conditions and friction stir welded joint properties has been discussed.

Welds in thermoplastic composite materials

NASA Astrophysics Data System (ADS)

Taylor, N. S.

Welding methods are reviewed that can be effectively used for joining of thermoplastic composites and continuous-fiber thermoplastics. Attention is given to the use of ultrasonic, vibration, hot-plate, resistance, and induction welding techniques. The welding techniques are shown to provide complementary weld qualities for the range of thermoplastic materials that are of interest to industrial and technological applications.

Variable polarity arc welding

NASA Technical Reports Server (NTRS)

Bayless, E. O., Jr.

1991-01-01

Technological advances generate within themselves dissatisfactions that lead to further advances in a process. A series of advances in welding technology which culminated in the Variable Polarity Plasma Arc (VPPA) Welding Process and an advance instituted to overcome the latest dissatisfactions with the process: automated VPPA welding are described briefly.

Laser Welding in Space

NASA Technical Reports Server (NTRS)

Workman, Gary L.; Kaukler, William F.

1989-01-01

Solidification type welding process experiments in conditions of microgravity were performed. The role of convection in such phenomena was examined and convective effects in the small volumes obtained in the laser weld zone were observed. Heat transfer within the weld was affected by acceleration level as indicated by the resulting microstructure changes in low gravity. All experiments were performed such that both high and low gravity welds occurred along the same weld beam, allowing the effects of gravity alone to be examined. Results indicate that laser welding in a space environment is feasible and can be safely performed IVA or EVA. Development of the hardware to perform the experiment in a Hitchhiker-g platform is recomended as the next step. This experiment provides NASA with a capable technology for welding needs in space. The resources required to perform this experiment aboard a Shuttle Hitchhiker-pallet are assessed. Over the four year period 1991 to 1994, it is recommended that the task will require 13.6 manyears and $914,900. In addition to demonstrating the technology and ferreting out the problems encountered, it is suggested that NASA will also have a useful laser materials processing facility for working with both the scientific and the engineering aspects of materials processing in space. Several concepts are also included for long-term optimization of available solar power through solar pumping solid state lasers directly for welding power.

Assessment of delta ferrite in multipass TIG welds of 40 mm thick SS 316L: A comparative study of ferrite number (FN) prediction and measurements

NASA Astrophysics Data System (ADS)

Buddu, Ramesh Kumar; Raole, P. M.; Sarkar, B.

2017-04-01

Austenitic stainless steels are widely used in the fabrication of fusion reactor major systems like vacuum vessel, divertor, cryostat and other structural components development. Multipass welding is used for the development of thick plates for the structural components fabrication. Due to the repeated weld thermal cycles, the microstructure adversely alters owing to the presence of complex phases like austenite, ferrite and delta ferrite and subsequently influences the mechanical properties like tensile and impact toughness of joints. The present paper reports the detail analysis of delta ferrite phase in welded region of 40 mm thick SS316L plates welded by special design multipass narrow groove TIG welding process under three different heat input conditions. The correlation of delta ferrite microstructure of different type structures acicular and vermicular is observed. The chemical composition of weld samples was used to predict the Ferrite Number (FN), which is representative form of delta ferrite in welds, with Schaeffler’s, WRC-1992 diagram and DeLong techniques by calculating the Creq and Nieq ratios and compared with experimental data of FN from Feritescope measurements. The low heat input conditions (1.67 kJ/mm) have produced higher FN (7.28), medium heat input (1.72 kJ/mm) shown FN (7.04) where as high heat input (1.87 kJ/mm) conditions has shown FN (6.68) decreasing trend and FN data is compared with the prediction methods.

Automatic programming of arc welding robots

NASA Astrophysics Data System (ADS)

Padmanabhan, Srikanth

Automatic programming of arc welding robots requires the geometric description of a part from a solid modeling system, expert weld process knowledge and the kinematic arrangement of the robot and positioner automatically. Current commercial solid models are incapable of storing explicitly product and process definitions of weld features. This work presents a paradigm to develop a computer-aided engineering environment that supports complete weld feature information in a solid model and to create an automatic programming system for robotic arc welding. In the first part, welding features are treated as properties or attributes of an object, features which are portions of the object surface--the topological boundary. The structure for representing the features and attributes is a graph called the Welding Attribute Graph (WAGRAPH). The method associates appropriate weld features to geometric primitives, adds welding attributes, and checks the validity of welding specifications. A systematic structure is provided to incorporate welding attributes and coordinate system information in a CSG tree. The specific implementation of this structure using a hybrid solid modeler (IDEAS) and an object-oriented programming paradigm is described. The second part provides a comprehensive methodology to acquire and represent weld process knowledge required for the proper selection of welding schedules. A methodology of knowledge acquisition using statistical methods is proposed. It is shown that these procedures did little to capture the private knowledge of experts (heuristics), but helped in determining general dependencies, and trends. A need was established for building the knowledge-based system using handbook knowledge and to allow the experts further to build the system. A methodology to check the consistency and validity for such knowledge addition is proposed. A mapping shell designed to transform the design features to application specific weld process schedules is described

Gas Tungsten Arc Welding. Welding Module 6. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching a three-unit module in gas tungsten arc welding. The module has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The basic principles involved in gas tungsten arc welding, supplies, and applications are covered. The materials included…

Report Summarizing the Effort Required to Initiate Welding of Irradiated Materials within the Welding Cubicle

DOE Office of Scientific and Technical Information (OSTI.GOV)

Frederick, Greg; Sutton, Benjamin J.; Tatman, Jonathan K.

The advanced welding facility within a hot cell at the Radiochemical Engineering Development Center of Oak Ridge National Laboratory (ORNL), which has been jointly funded by the U.S. Department of Energy (DOE), Office of Nuclear Energy, Light Water Reactor Sustainability Program and the Electric Power Research Institute, Long Term Operations Program and the Welding and Repair Technology Center, is in the final phase of development. Research and development activities in this facility will involve direct testing of advanced welding technologies on irradiated materials in order to address the primary technical challenge of helium induced cracking that can arise when conventionalmore » fusion welding techniques are utilized on neutron irradiated stainless steels and nickel-base alloys. This report details the effort that has been required since the beginning of fiscal year 2017 to initiate welding research and development activities on irradiated materials within the hot cell cubicle, which houses welding sub-systems that include laser beam welding (LBW) and friction stir welding (FSW) and provides material containment within the hot cell.« less

Welding and joining: A compilation

NASA Technical Reports Server (NTRS)

1975-01-01

A compilation is presented of NASA-developed technology in welding and joining. Topics discussed include welding equipment, techniques in welding, general bonding, joining techniques, and clamps and holding fixtures.

Health effects of welding.

PubMed

Antonini, James M

2003-01-01

Many of the epidemiology studies performed are difficult to compare because of differences in worker populations, industrial settings, welding techniques, duration of exposure, and other occupational exposures besides welding fumes. Some studies were conducted in carefully controlled work environments, others during actual workplace conditions, and some in laboratories. Epidemiology studies have shown that a large number of welders experience some type of respiratory illness. Respiratory effects seen in full-time welders have included bronchitis, airway irritation, lung function changes, and a possible increase in the incidence of lung cancer. Pulmonary infections are increased in terms of severity, duration, and frequency among welders. Although epidemiological studies have demonstrated an increase in pulmonary illness after exposure to welding fumes, little information of the causality, dose-response, and possible underlying mechanisms regarding the inhalation of welding fumes exists. Even less information is available about the neurological, reproductive, and dermal effects after welding fume exposure. Moreover, carcinogenicity and short-term and long-term toxicology studies of welding fumes in animals are lacing or incomplete. Therefore, an understanding of possible adverse health effects of exposure to welding fumes is essential to risk assessment and the development of prevention strategies and will impact a large population of workers.

Pipeline welding goes mechanized

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beeson, R.

1999-11-01

Spread four has bugs in the cornfield--but not to worry. The bug referred to here is a mechanized welding bug, specifically a single welding head, computer-aided gas metal arc (GMAW) system from CRC-Evans Automatic Welding powered by a Miller Electric XMT{reg{underscore}sign} 304 inverter-based welding machine. The bug operator and owner of 32 inverters is Welded Construction, L.P., of Perrysburgh, Ohio. Spread four is a 147-mile stretch of the Alliance Pipeline system (Alliance) cutting through the cornfields of northeast Iowa. While used successfully in Canada and Europe for onshore and offshore pipeline construction for 30 years, this is the first large-scalemore » use of mechanized welding in the US on a cross-country pipeline. On longer, larger-diameter and thicker-wall pipe projects--the Alliance mainline has 1,844 miles of pipe, most of it 36-in. diameter with a 0.622-in. wall thickness--mechanized GMAW offers better productivity than manual shielded metal arc welding (SMAW). In addition, high-strength steels, such as the API 5L Grade X70 pipe used on the Alliance, benefit from the low-hydrogen content of certain solid and tubular wire electrodes.« less

Capillary flow weld-bonding

NASA Technical Reports Server (NTRS)

Vaughan, R. W.; Jones, R. J. (Inventor)

1976-01-01

The invention of a weld-bonding technique for titanium plates was described. This involves fastening at least two plates of titanium together using spot-welding and applying a bead of adhesive along the edge of the resistance spot-welded joint which upon heating, flows and fills the separation between the joint components.

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy

PubMed Central

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-01-01

Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force. PMID:28788430

Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy.

PubMed

Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

2013-12-18

Friction Stir Welding (FSW) is a solid-state joining process; i.e. , no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.

Welding Development: Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Ding, Jeff

2007-01-01

This paper presents the basic understanding of the friction stir welding process. It covers process description, pin tool operation and materials, metal flow theory, mechanical properties, and materials welded using the process. It also discusses the thermal stir welding process and the differences between thermal stir and friction stir welding. MSFC weld tools used for development are also presented.

Shielding gas selection for increased weld penetration and productivity in GTA welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Leinonen, J.I.

1996-12-31

The effects of hydrogen and helium additions to the argon shielding gas on GTA weld pool profiles in the case of two austenitic stainless steel sheets 3 mm thick are investigated here in detail. One of the test steels shows good weldability, with a relatively deep, narrow weld pool profile, but the other is poorly weldable, with a shallow, wide weld pool when argon shielding gas is used. Bead-on-plate test welds were produced with arc shields of argon, argon with hydrogen additions of 2 to 18.2% and argon with helium additions of 20 to 80%. The hydrogen additions increases themore » depth of weld penetration in both test steels, but productivity with respect to maximum welding speed can be improved to an accepted level only with steel sheets of good weldability in terms of a relatively high depth/width (D/W) ratio. The depth of penetration in the test steel of good weldability increased somewhat with helium additions and the D/W ratio remained unchanged, while these parameters increased markedly in the poorly weldable steel when a He-20% Ar shielding gas was used and resembled those of the more weldable steel.« less

Determination of GTA Welding Efficiencies

DTIC Science & Technology

1993-03-01

continue on reverse if ncessary andidentify by block number) A method is developed for estimating welding efficiencies for moving arc GTAW processes...Dutta, Co-Advi r Department of Mechanical Engineering ii ABSTRACT A method is developed for estimating welding efficiencies for moving arc GTAW ...17 Figure 10. Miller Welding Equipment ............. ... 18 Figure 11. GTAW Torch Setup for Automatic Welding. . 19 Figure 12

Accelerated Post-Weld Natural Ageing in Ultrasonic Welding Aluminium 6111-T4 Automotive Sheet

NASA Astrophysics Data System (ADS)

Chen, Ying-Chun; Prangnell, Phil

In contrast to previously published reports, it is shown that there is an observable HAZ when ultrasonic spot welding (USW) automotive alloys, like AA6111-T4, the severity of which depends on the welding energy. Immediately after welding, softening is seen relative to the T4 condition, but this is rapidly recovered by natural ageing, which masks the presence of a HAZ, and the weld strength eventually exceeds that of the parent material. This behaviour is caused by dissolution of the solute clusters/GPZs in the T4 sheet, due to the high weld temperatures (> 400 °C), combined with accelerated post-weld natural ageing to a more advanced state than in the parent material. Modelling has demonstrated that this accelerated natural ageing behaviour can be attributed to an excess vacancy concentration generated by the USW process.

Method for enhanced control of welding processes

DOEpatents

Sheaffer, Donald A.; Renzi, Ronald F.; Tung, David M.; Schroder, Kevin

2000-01-01

Method and system for producing high quality welds in welding processes, in general, and gas tungsten arc (GTA) welding, in particular by controlling weld penetration. Light emitted from a weld pool is collected from the backside of a workpiece by optical means during welding and transmitted to a digital video camera for further processing, after the emitted light is first passed through a short wavelength pass filter to remove infrared radiation. By filtering out the infrared component of the light emitted from the backside weld pool image, the present invention provides for the accurate determination of the weld pool boundary. Data from the digital camera is fed to an imaging board which focuses on a 100.times.100 pixel portion of the image. The board performs a thresholding operation and provides this information to a digital signal processor to compute the backside weld pool dimensions and area. This information is used by a control system, in a dynamic feedback mode, to automatically adjust appropriate parameters of a welding system, such as the welding current, to control weld penetration and thus, create a uniform weld bead and high quality weld.

Welding wire pressure sensor assembly

NASA Technical Reports Server (NTRS)

Morris, Timothy B. (Inventor); Milly, Peter F., Sr. (Inventor); White, J. Kevin (Inventor)

1994-01-01

The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

NASA Technical Reports Server (NTRS)

Querin, Joseph A.; Schneider, Judy A.

2008-01-01

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

Automated Variable-Polarity Plasma-Arc Welding

NASA Technical Reports Server (NTRS)

Numes, A. C., Jr.; Bayless, E. O., Jr.; Jones, S. C., III; Munafo, P.; Munafo, A.; Biddle, A.; Wilson, W.

1984-01-01

Variable-polarity plasma-arc methods produces better welds at lower cost than gas-shielded tungsten-arc welding in assemblies. Weld porosity very low and costs of joint preparation, depeaking, inspection, and weld repair minimized.

Bronchial reactions to exposure to welding fumes.

PubMed

Contreras, G R; Chan-Yeung, M

1997-11-01

To study the airway response and its mechanism to welding fumes in six welders with respiratory symptoms. Methacholine and welding challenge tests were carried out. The concentration of welding fumes during the exposure test was measured. On two subjects who developed bronchoconstricition to welding challenge, additional tests were carried out including prick, patch, and inhalation challenges with metal salt solutions. Three subjects developed immediate bronchial reaction to exposure to welding fume; one to mild steel and stainless steel welding, another to mild steel and galvanised welding, and one only to galvanised welding. They all had a moderate to pronounced degree of non-specific bronchial hyperresponsiveness. The concentration of fumes during welding tests, particularly to galvanised welding, was high. An inhalation challenge test with zinc chloride salt solution in two subjects who reacted to galvanised welding was negative. Prick and patch tests with zinc chloride were also negative. The airway response to welding in these subjects is non-specific and is due to irritation rather than to sensitisation.

Ultrasonic Welding of Hybrid Joints

NASA Astrophysics Data System (ADS)

Wagner, Guntram; Balle, Frank; Eifler, Dietmar

2012-03-01

A central research field of the Institute of Materials Science and Engineering at the University of Kaiserslautern (WKK), Germany, is the realization of innovative hybrid joints by ultrasonic metal welding. This article gives an overview of suitable ultrasonic welding systems as well as of essential machine and material parameters, which influence the quality of the welds. Besides the ultrasonic welding of dissimilar metals such as Al to Cu or Al to steels, the welds between newly developed materials like aluminum foam sandwiches or flat flexible cables also can be realized. Moreover, the joining of glass and ceramic to sheet metals is a point of interest at the WKK. By using the ultrasonic metal welding process, it is possible to realize metal/glass welds with tensile shear strengths of 50 MPa. For metal/ceramic joints, the shear strengths values up to 150 MPa were measured. Finally, selected results about the occurring bonding mechanisms will be discussed.

Laser welding of fused quartz

DOEpatents

Piltch, Martin S.; Carpenter, Robert W.; Archer, III, McIlwaine

2003-06-10

Refractory materials, such as fused quartz plates and rods are welded using a heat source, such as a high power continuous wave carbon dioxide laser. The radiation is optimized through a process of varying the power, the focus, and the feed rates of the laser such that full penetration welds may be accomplished. The process of optimization varies the characteristic wavelengths of the laser until the radiation is almost completely absorbed by the refractory material, thereby leading to a very rapid heating of the material to the melting point. This optimization naturally occurs when a carbon dioxide laser is used to weld quartz. As such this method of quartz welding creates a minimum sized heat-affected zone. Furthermore, the welding apparatus and process requires a ventilation system to carry away the silicon oxides that are produced during the welding process to avoid the deposition of the silicon oxides on the surface of the quartz plates or the contamination of the welds with the silicon oxides.

Automatic welding systems for large ship hulls

NASA Astrophysics Data System (ADS)

Arregi, B.; Granados, S.; Hascoet, JY.; Hamilton, K.; Alonso, M.; Ares, E.

2012-04-01

Welding processes represents about 40% of the total production time in shipbuilding. Although most of the indoor welding work is automated, outdoor operations still require the involvement of numerous operators. To automate hull welding operations is a priority in large shipyards. The objective of the present work is to develop a comprehensive welding system capable of working with several welding layers in an automated way. There are several difficulties for the seam tracking automation of the welding process. The proposed solution is the development of a welding machine capable of moving autonomously along the welding seam, controlling both the position of the torch and the welding parameters to adjust the thickness of the weld bead to the actual gap between the hull plates.

Friction Stir Welding Development

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1998-01-01

The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.

Welding and Weldability of AZ31B by Gas Tungsten Arc and Laser Beam Welding Processes

NASA Astrophysics Data System (ADS)

Lathabai, S.; Barton, K. J.; Harris, D.; Lloyd, P. G.; Viano, D. M.; McLean, A.

Welding will play an important role in the fabrication of modular lightweight structures based on magnesium alloy die castings, extrusion profiles and wrought products. Minimisation of rejection rates during fabrication requires that satisfactory weldability be established for a particular combination of materials and welding procedures. In this paper, we present the results of a study to quantify the weldability of wrought alloy AZ31B by gas tungsten arc (GTA) and laser beam (LB) welding processes. The susceptibility to weld metal solidification cracking was evaluated using the Circular Patch weldability test. Operating windows of welding parameters for crack-free and porosity-free GTA and LB welding were identified, based on which welding procedures were developed for sheet and plate AZ31B. The microstructure and mechanical properties of welded test plates were assessed, leading to a better understanding of microstructurat development and structure-property relationships in GTA and LB weldments in AZ31B.

Identification of the Quality Spot Welding used Non Destructive Test-Ultrasonic Testing: (Effect of Welding Time)

NASA Astrophysics Data System (ADS)

Sifa, A.; Endramawan, T.; Badruzzaman

2017-03-01

Resistance Spot Welding (RSW) is frequently used as one way of welding is used in the manufacturing process, especially in the automotive industry [4][5][6][7]. Several parameters influence the process of welding points. To determine the quality of a welding job needs to be tested, either by damaging or testing without damage, in this study conducted experimental testing the quality of welding or identify quality of the nugget by using Non-Destructive Test (NDT) -Ultrasonic Testing (UT), in which the identification of the quality of the welding is done with parameter thickness of worksheet after welding using NDT-UT with use same material worksheet and have more thickness of worksheet, the thickness of the worksheet single plate 1mm, with the capability of propagation Ultrasonic Testing (UT) standard limited> 3 mm [1], welding process parameters such as the time difference between 1-10s and the welding current of 8 KV, visually Heat Affected Zone ( HAZ ) have different results due to the length of time of welding. UT uses a probe that is used with a frequency of 4 MHz, diameter 10 mm, range 100 and the couplant used is oil. Identification techniques using drop 6dB, with sound velocity 2267 m / s of Fe, with the result that the effect of the Welding time affect the size of the HAZ, identification with the lowest time 1s show results capable identified joined through NDT - UT.

Shielded Metal Arc Welding. Welding Module 4. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching an eight-unit module in shielded metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety; theory, power sources, and…

Gas Metal Arc Welding. Welding Module 5. Instructor's Guide.

ERIC Educational Resources Information Center

Missouri Univ., Columbia. Instructional Materials Lab.

This guide is intended to assist vocational educators in teaching an eight-unit module in gas metal arc welding. The module is part of a welding curriculum that has been designed to be totally integrated with Missouri's Vocational Instruction Management System. The following topics are covered in the module: safety and testing, gas metal arc…

Pre-resistance-welding resistance check

DOEpatents

Destefan, Dennis E.; Stompro, David A.

1991-01-01

A preweld resistance check for resistance welding machines uses an open circuited measurement to determine the welding machine resistance, a closed circuit measurement to determine the parallel resistance of a workpiece set and the machine, and a calculation to determine the resistance of the workpiece set. Any variation in workpiece set or machine resistance is an indication that the weld may be different from a control weld.

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing.

PubMed

Villegas, Irene F; Palardy, Genevieve

2016-02-11

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints.

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing

PubMed Central

Villegas, Irene F.; Palardy, Genevieve

2016-01-01

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints. PMID:26890931

Automatic monitoring of vibration welding equipment

DOEpatents

Spicer, John Patrick; Chakraborty, Debejyo; Wincek, Michael Anthony; Wang, Hui; Abell, Jeffrey A; Bracey, Jennifer; Cai, Wayne W

2014-10-14

A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

APPARATUS AND METHOD FOR ARC WELDING

DOEpatents

Noland, R.A.; Stone, C.C.

1960-05-10

An apparatus and method are given for forming a welding arc which is rotated by a magnetic field very rapidly about an annular electrode so that a weld is produced simultaneously over all points of an annular or closed path. This invention inhibits outgassing from the jacket of a fuel slug which is being welded by adjusting the pressure throughout the welding cycle to establish a balance between the gas pressure within the jacket and that of the atmosphere surrounding the jacket. Furthermore, an improved control of the magnetic field producing rotation of the welding arc is disclosed whereby this rotation is prevented from splashing about the metal being welded as the welding arc makes it molten.

Replacement of seam welded hot reheat pipe using narrow groove GTA machine welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Richardson, R.R.; Yanes, J.; Bryant, R.

1995-12-31

Southern California Edison, recognizing a potential safety concern, scrutinized its existing seam welded hot reheat pipe manufactured by the same supplier as that which failed. Alternatives were narrowed to two in dealing with the installed seam welded pipe. The overriding consideration, however, was one of safety. With this in mind, the utility company evaluated replacement of the seam welded hot reheat pipe with seamless pipe or increasing the frequency of its inspection program. Although increased inspection was much costly, pipe replacement was chosen due to potential safety concerns with seam welded pipe even with more frequent inspection. The utility companymore » then proceeded to determine the most effective method to complete this work. Analysis showed machine-made (automatic) gas tungsten arc welds (GTAW) as the method of choice due to cleanliness and superior mechanical properties. In conjunction with this method, the narrow groove (3{degree} bevel) weld joint as opposed to the traditional groove (37 1/2{degree} bevel) was shown to provide significant technical advantages.« less

Prediction Analysis of Weld-Bead and Heat Affected Zone in TIG welding using Artificial Neural Networks

NASA Astrophysics Data System (ADS)

Saldanha, Shamith L.; Kalaichelvi, V.; Karthikeyan, R.

2018-04-01

TIG Welding is a high quality form of welding which is very popular in industries. It is one of the few types of welding that can be used to join dissimilar metals. Here a weld joint is formed between stainless steel and monel alloy. It is desired to have control over the weld geometry of such a joint through the adjustment of experimental parameters which are welding current, wire feed speed, arc length and the shielding gas flow rate. To facilitate the automation of the same, a model of the welding system is needed. However the underlying welding process is complex and non-linear, and analytical methods are impractical for industrial use. Therefore artificial neural networks (ANN) are explored for developing the model, as they are well-suited for modelling non-linear multi-variate data. Feed-forward neural networks with backpropagation training algorithm are used, and the data for training the ANN taken from experimental work. There are four outputs corresponding to the weld geometry. Different training and testing phases were carried out using MATLAB software and ANN approximates the given data with minimum amount of error.

Characteristics comparison of weld metal zones welded to cast and forged steels for piston crown material

NASA Astrophysics Data System (ADS)

Moon, Kyung-Man; Kim, Yun-Hae; Lee, Myeong-Hoon; Baek, Tae-Sil

2015-03-01

An optimum repair welding for the piston crown which is one of the engine parts exposed to the combustion chamber is considered to be very important to prolong the engine lifetime from an economical point of view. In this study, two types of filler metals such as 1.25Cr-0.5Mo, 0.5Mo were welded with SMAW method and the other two types of filler metals such as Inconel 625 and 718 were welded with GTAW method, respectively, and the used base metals were the cast and forged steels of the piston crown material. The weld metal zones welded with Inconel 625 and 718 filler metals exhibited higher corrosion resistance compared to 1.25Cr-0.5Mo and 0.5Mo filler metals. In particular, the weld metal zone welded with Inconel 718 and 0.5Mo, filler metals indicated the best and worst corrosion resistance, respectively. Consequently, it is suggested that the corrosion resistance of the weld metal zone surely depends on the chemical components of each filler metal and welding method irrespective of the types of piston crown material.

Innovative Tools Advance Revolutionary Weld Technique

NASA Technical Reports Server (NTRS)

2009-01-01

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe

Bronchial reactions to exposure to welding fumes.

PubMed Central

Contreras, G R; Chan-Yeung, M

1997-01-01

OBJECTIVES: To study the airway response and its mechanism to welding fumes in six welders with respiratory symptoms. METHODS: Methacholine and welding challenge tests were carried out. The concentration of welding fumes during the exposure test was measured. On two subjects who developed bronchoconstricition to welding challenge, additional tests were carried out including prick, patch, and inhalation challenges with metal salt solutions. RESULTS: Three subjects developed immediate bronchial reaction to exposure to welding fume; one to mild steel and stainless steel welding, another to mild steel and galvanised welding, and one only to galvanised welding. They all had a moderate to pronounced degree of non-specific bronchial hyperresponsiveness. The concentration of fumes during welding tests, particularly to galvanised welding, was high. An inhalation challenge test with zinc chloride salt solution in two subjects who reacted to galvanised welding was negative. Prick and patch tests with zinc chloride were also negative. CONCLUSION: The airway response to welding in these subjects is non-specific and is due to irritation rather than to sensitisation. PMID:9538358

Multi-mode ultrasonic welding control and optimization

DOEpatents

Tang, Jason C.H.; Cai, Wayne W

2013-05-28

A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

PubMed Central

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-01-01

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations. PMID:28772809

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy.

PubMed

Peng, He; Chen, Daolun; Jiang, Xianquan

2017-04-25

The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique-ultrasonic spot welding (USW)-at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with "river-flow" patterns and characteristic fatigue striations.

Vacuum mechatronics

NASA Technical Reports Server (NTRS)

Hackwood, Susan; Belinski, Steven E.; Beni, Gerardo

1989-01-01

The discipline of vacuum mechatronics is defined as the design and development of vacuum-compatible computer-controlled mechanisms for manipulating, sensing and testing in a vacuum environment. The importance of vacuum mechatronics is growing with an increased application of vacuum in space studies and in manufacturing for material processing, medicine, microelectronics, emission studies, lyophylisation, freeze drying and packaging. The quickly developing field of vacuum mechatronics will also be the driving force for the realization of an advanced era of totally enclosed clean manufacturing cells. High technology manufacturing has increasingly demanding requirements for precision manipulation, in situ process monitoring and contamination-free environments. To remove the contamination problems associated with human workers, the tendency in many manufacturing processes is to move towards total automation. This will become a requirement in the near future for e.g., microelectronics manufacturing. Automation in ultra-clean manufacturing environments is evolving into the concept of self-contained and fully enclosed manufacturing. A Self Contained Automated Robotic Factory (SCARF) is being developed as a flexible research facility for totally enclosed manufacturing. The construction and successful operation of a SCARF will provide a novel, flexible, self-contained, clean, vacuum manufacturing environment. SCARF also requires very high reliability and intelligent control. The trends in vacuum mechatronics and some of the key research issues are reviewed.

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

NASA Technical Reports Server (NTRS)

Querin, Joseph A.; Schneider, Judy A.

2008-01-01

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

Lightweight, High-Current Welding Gun

NASA Technical Reports Server (NTRS)

Starck, Thomas F.; Brennan, Andrew D.

1989-01-01

Lighweight resistance-welding, hand-held gun supplies alternating or direct current over range of 600 to 4,000 A and applies forces from 40 to 60 lb during welding. Used to weld metal sheets in multilayered stacks.

Welding skate with computerized controls

NASA Technical Reports Server (NTRS)

Wall, W. A., Jr.

1968-01-01

New welding skate concept for automatic TIG welding of contoured or double-contoured parts combines lightweight welding apparatus with electrical circuitry which computes the desired torch angle and positions a torch and cold-wire guide angle manipulator.

29 CFR 1910.255 - Resistance welding.

Code of Federal Regulations, 2012 CFR

2012-07-01

..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

29 CFR 1910.255 - Resistance welding.

Code of Federal Regulations, 2014 CFR

2014-07-01

..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

29 CFR 1910.255 - Resistance welding.

Code of Federal Regulations, 2011 CFR

2011-07-01

..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

29 CFR 1910.255 - Resistance welding.

Code of Federal Regulations, 2010 CFR

2010-07-01

..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

29 CFR 1910.255 - Resistance welding.

Code of Federal Regulations, 2013 CFR

2013-07-01

..., the secondary of all welding transformers used in multispot, projection and seam welding machines... counterbalancing impractical or unnecessary. (2) Safety chains. All portable welding guns, transformers and related...) Grounding. The secondary and case of all portable welding transformers shall be grounded. Secondary...

Laser penetration spike welding: a welding tool enabling novel process and design opportunities

NASA Astrophysics Data System (ADS)

Dijken, Durandus K.; Hoving, Willem; De Hosson, J. Th. M.

2002-06-01

A novel method for laser welding for sheet metal. is presented. This laser spike welding method is capable of bridging large gaps between sheet metal plates. Novel constructions can be designed and manufactured. Examples are light weight metal epoxy multi-layers and constructions having additional strength with respect to rigidity and impact resistance. Its capability to bridge large gaps allows higher dimensional tolerances in production. The required laser systems are commercially available and are easily implemented in existing production lines. The lasers are highly reliable, the resulting spike welds are quickly realized and the cost price per weld is very low.

Field Study: A Welding Survey of the Blackhawk Technical Institute Industries (Up-dating the Welding Curriculum).

ERIC Educational Resources Information Center

Lesch, Gerald E.

In 1972, the welding department personnel at Blackhawk Technical Institute in Wisconsin undertook the project of updating the curriculum of their one-year welding degree program. A study was conducted of local welding industries to determine hiring policies, the tools and equipment a beginning welder should purchase, the types of welding processes…

Evaluation of the AISI 904L Alloy Weld Overlays Obtained by GMAW and Electro-Slag Welding Processes

NASA Astrophysics Data System (ADS)

Jorge, Jorge C. F.; Meira, O. G.; Madalena, F. C. A.; de Souza, L. F. G.; Araujo, L. S.; Mendes, M. C.

2017-05-01

The use of superaustenitic stainless steels (SASS) as an overlay replacement for nickel-based alloys can be an interesting alternative for the oil and gas industries, due to its lower cost, when compared to superalloys. Usually, the deposition is made with several welding passes by using conventional arc welding processes, such as gas tungsten arc welding (GTAW) or gas metal arc welding (GMAW) processes. In this respect, electro-slag welding (ESW), which promotes high heat inputs and low dilution of the welds, can also be attractive for this application, as it provides a higher productivity, once only one layer is needed for the deposition of the minimum thickness required. The present work evaluates the behavior of an AISI 904L SASS weld overlay deposited on a carbon steel ASTM A516 Grade 70 by ESW and GMAW processes. Both as-welded and heat-treated conditions were evaluated and compared. A multipass welding by GMAW process with three layers and 48 passes was performed on 12.5 × 200 × 250 mm steel plates with average welding energy of 1.0 kJ/mm. For ESW process, only one layer was deposited on 50 × 400 × 400 mm steel plates with average welding energy of 11.7 kJ/mm. After welding, a post-weld heat treatment (PWHT) at 620 °C for 10 h was performed in half of the steel plate, in order to allow the comparison between this condition and the as-welded one. For both processes, the austenitic microstructure of the weld deposits was characterized by optical microscopy and scanning electron microscopy with electron backscatter diffraction. A low proportion of secondary phases were observed in all conditions, and the PWHT did not promote significant changes on the hardness profile. Martensite for GMAW process and bainite for ESW process were the microstructural constituents observed at the coarse grain heat-affected zone, due to the different cooling rates. For ESW process, no evidences of partially diluted zones were found. As a consequence of the microstructural

Real time computer controlled weld skate

NASA Technical Reports Server (NTRS)

Wall, W. A., Jr.

1977-01-01

A real time, adaptive control, automatic welding system was developed. This system utilizes the general case geometrical relationships between a weldment and a weld skate to precisely maintain constant weld speed and torch angle along a contoured workplace. The system is compatible with the gas tungsten arc weld process or can be adapted to other weld processes. Heli-arc cutting and machine tool routing operations are possible applications.

Development of Weld Metal Microstructures in Pulsed Laser Welding of Duplex Stainless Steel

NASA Astrophysics Data System (ADS)

Mirakhorli, F.; Malek Ghaini, F.; Torkamany, M. J.

2012-10-01

The microstructure of the weld metal of a duplex stainless steel made with Nd:YAG pulsed laser is investigated at different travel speeds and pulse frequencies. In terms of the solidification pattern, the weld microstructure is shown to be composed of two distinct zones. The presence of two competing heat transfer channels to the relatively cooler base metal and the relatively hotter previous weld spot is proposed to develop two zones. At high overlapping factors, an array of continuous axial grains at the weld centerline is formed. At low overlapping factors, in the zone of higher cooling rate, a higher percentage of ferrite is transformed to austenite. This is shown to be because with extreme cooling rates involved in pulsed laser welding with low overlapping, the ferrite-to-austenite transformation can be limited only to the grain boundaries.

Ternary gas plasma welding torch

NASA Technical Reports Server (NTRS)

Rybicki, Daniel J. (Inventor); Mcgee, William F. (Inventor); Waldron, Douglas J. (Inventor)

1995-01-01

A plasma arc welding torch is discussed. A first plasma gas is directed through the body of the welding torch and out of the body across the tip of a welding electrode disposed at the forward end of the body. A second plasma gas is disposed for flow through a longitudinal bore in the electrode. The second plasma gas enters one end of the electrode and exits the electrode at the tip thereof for co-acting with the electric welding arc to produce the desired weld. A shield gas is directed through the torch body and circulates around the head of the torch adjacent to the electrode tip.

Theoretical Foundation for Weld Modeling

NASA Technical Reports Server (NTRS)

Traugott, S.

1986-01-01

Differential equations describe physics of tungsten/inert-gas and plasma-arc welding in aluminum. Report collects and describes necessary theoretical foundation upon which numerical welding model is constructed for tungsten/inert gas or plasma-arc welding in aluminum without keyhole. Governing partial differential equations for flow of heat, metal, and current given, together with boundary conditions relevant to welding process. Numerical estimates for relative importance of various phenomena and required properties of 2219 aluminum included

Effects of Sealing Run Welding with Defocused Laser Beam on the Quality of T-joint Fillet Weld

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

Fillet weld is the predominant weld type used for connecting different elements e.g. in shipbuilding, offshore and bridge structures. One of prevalent research questions is the structural integrity of the welded joint. Post weld improvement techniques are being actively researched, as high stress areas like an incomplete penetration on the root side or fluctuations in penetration depth cannot be avoided. Development of laser and laser-arc hybrid welding processes have greatly contributed to increase of production capacity and reduction of heat-induced distortions by producing single pass full penetration welds in thin- and medium thickness structural steel parts. Present study addresses the issue of how to improve the quality of the fillet welds by welding the sealing run on the root side with defocused laser beam. Welds having incomplete or excessive penetration were produced with several beam angles and laser beam spot sizes on surface. As a conclusion, significant decrease or even complete elimination of the seam irregularities, which act as the failure starting points during service, is achieved.

Welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems using fundamental- and higher-resonance frequencies.

PubMed

Tsujino, Jiromaru; Hongoh, Misugi; Yoshikuni, Masafumi; Hashii, Hidekazu; Ueoka, Tetsugi

2004-04-01

The welding characteristics of 27, 40 and 67 kHz ultrasonic plastic welding systems that are driven at only the fundamental-resonance frequency vibration were compared, and also those of the welding systems that were driven at the fundamental and several higher resonance frequencies simultaneously were studied. At high frequency, welding characteristics can be improved due to the larger vibration loss of plastic materials. For welding of rather thin or small specimens, as the fundamental frequency of these welding systems is higher and the numbers of driven higher frequencies are driven simultaneously, larger welded area and weld strength were obtained.

Robot welding process control

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1991-01-01

This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon.

Development of technique for laser welding of biological tissues using laser welding device and nanocomposite solder.

PubMed

Gerasimenko, A; Ichcitidze, L; Podgaetsky, V; Ryabkin, D; Pyankov, E; Saveliev, M; Selishchev, S

2015-08-01

The laser device for welding of biological tissues has been developed involving quality control and temperature stabilization of weld seam. Laser nanocomposite solder applied onto a wound to be weld has been used. Physicochemical properties of the nanocomposite solder have been elucidated. The nature of the tissue-organizing nanoscaffold has been analyzed at the site of biotissue welding.

The keyhole region in VPPA welds

NASA Technical Reports Server (NTRS)

Walsh, Daniel W.

1988-01-01

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. The effects of microsegregation and transient weld stress on macrosegregation in the weld tool are examined. In addition the electrical character of straight and reverse polarity portions of the arc cycle were characterized. The results of the former study indicate that alloy 2219 is weldable because large liquid volumes are available during latter stages of weld solidification. Strains in the pool region, acting in conjunction with weld microsegregation can produce macrosegregation great enough to produce radiographic contrast effects in welds. Mechanisms of surface copper enrichment were identified. The latter study has demonstrated that increased heat is delivered to workpieces if the reverse polarity proportion of the weld cycle is increased. Current in the straight polarity portion of the welding cycle increased as the reverse cycle proportion increased. Voltage during reverse polarity segments is large.

Natural vacuum electronics

NASA Technical Reports Server (NTRS)

Leggett, Nickolaus

1990-01-01

The ambient natural vacuum of space is proposed as a basis for electron valves. Each valve is an electron controlling structure similiar to a vacuum tube that is operated without a vacuum sustaining envelope. The natural vacuum electron valves discussed offer a viable substitute for solid state devices. The natural vacuum valve is highly resistant to ionizing radiation, system generated electromagnetic pulse, current transients, and direct exposure to space conditions.

Method for controlling gas metal arc welding

DOEpatents

Smartt, Herschel B.; Einerson, Carolyn J.; Watkins, Arthur D.

1989-01-01

The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections.

Welding parameter optimization of alloy material by friction stir welding using Taguchi approach and design of experiments

NASA Astrophysics Data System (ADS)

Karwande, Amit H.; Rao, Seeram Srinivasa

2018-04-01

Friction stir welding (FSW) a welding process in which metals are joint by melting them at their solid state. In different engineering areas such as civil, mechanical, naval and aeronautical engineering beams are widely used of the magnesium alloys for different applications and that are joined by conventional inert gas welding process. Magnesium metal has less density and low melting point for that reason large heat generation in the common welding process so its necessity to adapt new welding process. FSW process increases the weld quality which observed under various mechanical testing by using different tool size.

Research and application of self - propagating welding technology

NASA Astrophysics Data System (ADS)

Ma, Yunhe; Li, Zhizun; Wang, Jianjiang; Sun, Liming

2018-04-01

Self-propagating welding is an important application area of self-propagating high-temperature synthesis technology (SHS technology), suitable for special environment and special materials welding. This paper briefly introduces the principle of self - propagating welding and its technical characteristics, and briefly summarizes the current research and application of SHS welding around three aspects of thin film welding, welding of refractory welding and emergency welding of battlefield.

Apparatus for maintaining aligment of a shrinking weld joint in an electron-beam welding operation

DOEpatents

Trent, J.B.; Murphy, J.L.

1980-01-03

The invention is directed to an apparatus for automatically maintaining a shrinking weld joint in alignement with an electron beam during an electron-beam multipass-welding operation. The apparatus utilizes a bias means for continually urging a workpiece-supporting face plate away from a carriage mounted base that rotatably supports the face plate. The extent of displacement of the face plate away from the base in indicative of the shrinkage occuring in the weld joint area. This displacement is measured and is used to move the base on the carriage a distance equal to one-half the displacement for aligning the weld joint with the electron beam during each welding pass.

Mechanical properties of thin films of laser-welded titanium and their associated welding defects.

PubMed

Wu, Yulu; Xin, Haitao; Zhang, Chunbao; Tang, Zhongbin; Zhang, Zhiyuan; Wang, Weifeng

2014-11-01

The aim of this study was to evaluate the mechanical properties of thin films of laser-welded cast titanium using an interference strain/displacement gauge (ISDG) and to analyze factors that affect laser welding. Dog-bone-shaped small specimens of cast titanium were prepared by wire cutting after they were laser-welded. The specimens were divided into three groups according to the gap distance of the laser weld; the control was non-welded titanium. Small specimens without cast defects detected by X-ray screening were measured by a tensile test machine using ISDG, and stress-strain curves were drawn. Finally, the fracture texture was analyzed. The ultimate tensile strengths (UTSs) of specimens with a gap distance of 0.00, 0.25, and 0.50 mm were 492.16 ± 33.19, 488.09 ± 43.18, and 558.45 ± 10.80 MPa, respectively. There were no significant differences in UTS between the test groups and the control group (p > 0.05). However, the plastic deformation and the percent elongation increased as the gap distance increased. Incomplete penetration defects appeared in groups that had small gap distances, which may have affected the properties of the laser-welded titanium. However, the welding material was still pure titanium. These results suggest that an appropriate gap distance should be maintained to improve the application of dental laser welding.

CRADA Final Report: Weld Predictor App

DOE Office of Scientific and Technical Information (OSTI.GOV)

Billings, Jay Jay

Welding is an important manufacturing process used in a broad range of industries and market sectors, including automotive, aerospace, heavy manufacturing, medical, and defense. During welded fabrication, high localized heat input and subsequent rapid cooling result in the creation of residual stresses and distortion. These residual stresses can significantly affect the fatigue resistance, cracking behavior, and load-carrying capacity of welded structures during service. Further, additional fitting and tacking time is often required to fit distorted subassemblies together, resulting in non-value added cost. Using trial-and-error methods to determine which welding parameters, welding sequences, and fixture designs will most effectively reduce distortionmore » is a time-consuming and expensive process. For complex structures with many welds, this approach can take several months. For this reason, efficient and accurate methods of mitigating distortion are in-demand across all industries where welding is used. Analytical and computational methods and commercial software tools have been developed to predict welding-induced residual stresses and distortion. Welding process parameters, fixtures, and tooling can be optimized to reduce the HAZ softening and minimize weld residual stress and distortion, improving performance and reducing design, fabrication and testing costs. However, weld modeling technology tools are currently accessible only to engineers and designers with a background in finite element analysis (FEA) who work with large manufacturers, research institutes, and universities with access to high-performance computing (HPC) resources. Small and medium enterprises (SMEs) in the US do not typically have the human and computational resources needed to adopt and utilize weld modeling technology. To allow an engineer with no background in FEA and SMEs to gain access to this important design tool, EWI and the Ohio Supercomputer Center (OSC) developed the online

A comparison of the physics of Gas Tungsten Arc Welding (GTAW), Electron Beam Welding (EBW), and Laser Beam Welding (LBW)

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.

1985-01-01

The physics governing the applicability and limitations of gas tungsten arc (GTA), electron beam (EB), and laser beam (LB) welding are compared. An appendix on the selection of laser welding systems is included.

INERT GAS SHIELD FOR WELDING

DOEpatents

Jones, S.O.; Daly, F.V.

1958-10-14

S>An inert gas shield is presented for arc-welding materials such as zirconium that tend to oxidize rapidly in air. The device comprises a rectangular metal box into which the welding electrode is introduced through a rubber diaphragm to provide flexibility. The front of the box is provided with a wlndow having a small hole through which flller metal is introduced. The box is supplied with an inert gas to exclude the atmosphere, and with cooling water to promote the solidification of the weld while in tbe inert atmosphere. A separate water-cooled copper backing bar is provided underneath the joint to be welded to contain the melt-through at the root of the joint, shielding the root of the joint with its own supply of inert gas and cooling the deposited weld metal. This device facilitates the welding of large workpieces of zirconium frequently encountered in reactor construction.

Microstructure and fatigue resistance of high strength dual phase steel welded with gas metal arc welding and plasma arc welding processes

NASA Astrophysics Data System (ADS)

Ahiale, Godwin Kwame; Oh, Yong-Jun; Choi, Won-Doo; Lee, Kwang-Bok; Jung, Jae-Gyu; Nam, Soo Woo

2013-09-01

This study presents the microstructure and high cycle fatigue performance of lap shear joints of dual phase steel (DP590) welded using gas metal arc welding (GMAW) and plasma arc welding (PAW) processes. High cycle fatigue tests were conducted on single and double lap joints under a load ratio of 0.1 and a frequency of 20 Hz. In order to establish a basis for comparison, both weldments were fabricated to have the same weld depth in the plate thickness. The PAW specimens exhibited a higher fatigue life, a gentle S-N slope, and a higher fatigue limit than the GMAW specimens. The improvement in the fatigue life of the PAW specimens was primarily attributed to the geometry effect that exhibited lower and wider beads resulting in a lower stress concentration at the weld toe where cracks initiate and propagate. Furthermore, the microstructural constituents in the heat-affected zone (HAZ) of the PAW specimens contributed to the improvement. The higher volume fraction of acicular ferrite in the HAZ beneath the weld toe enhanced the PAW specimen's resistance to fatigue crack growth. The double lap joints displayed a higher fatigue life than the single lap joints without changing the S-N slope.

Technology of welding aluminum alloys-IV

NASA Technical Reports Server (NTRS)

Ginez, R.; Lewis, J. R.; Millett, A. U.; Saenger, K. A.; Skelly, J. K.; Standiford, V. E.; Whiteman, J. O.

1978-01-01

Skate-weld carriage and track assembly were developed for controlled fusion welding on compound-curvature surfaces. Unlike fixed-position carriage used for vertical, horizontal, and circumferential welding, carriage has suspension system that permits angular positioning of weld head on carriage. It also has carriage-and-drive track mechanism capable of traveling over compound curvatures. Carriage is designed with universal mounting platform so that slim tools, weld heads, or X-ray units can be interchanged without need for realinement.

Method for controlling gas metal arc welding

DOEpatents

Smartt, H.B.; Einerson, C.J.; Watkins, A.D.

1987-08-10

The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections. 3 figs., 1 tab.

VACUUM TRAP

DOEpatents

Gordon, H.S.

1959-09-15

An improved adsorption vacuum trap for use in vacuum systems was designed. The distinguishing feature is the placement of a plurality of torsionally deformed metallic fins within a vacuum jacket extending from the walls to the central axis so that substantially all gas molecules pass through the jacket will impinge upon the fin surfaces. T fins are heated by direct metallic conduction, thereby ol taining a uniform temperature at the adeorbing surfaces so that essentially all of the condensible impurities from the evacuating gas are removed from the vacuum system.

46 CFR 154.660 - Pipe welding.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 46 Shipping 5 2010-10-01 2010-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet Part 57 of this chapter. (b) Longitudinal butt welds...

46 CFR 154.660 - Pipe welding.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 46 Shipping 5 2012-10-01 2012-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt welds...

46 CFR 154.660 - Pipe welding.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 5 2011-10-01 2011-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet Part 57 of this chapter. (b) Longitudinal butt welds...

46 CFR 154.660 - Pipe welding.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 46 Shipping 5 2013-10-01 2013-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt welds...

46 CFR 154.660 - Pipe welding.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 46 Shipping 5 2014-10-01 2014-10-01 false Pipe welding. 154.660 Section 154.660 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SAFETY STANDARDS FOR... § 154.660 Pipe welding. (a) Pipe welding must meet part 57 of this chapter. (b) Longitudinal butt welds...

Alternative welding reconditioning solutions without post welding heat treatment of pressure vessel

NASA Astrophysics Data System (ADS)

Cicic, D. T.; Rontescu, C.; Bogatu, A. M.; Dijmărescu, M. C.

2017-08-01

In pressure vessels, working on high temperature and high pressure may appear some defects, cracks for example, which may lead to failure in operation. When these nonconformities are identified, after certain examination, testing and result interpretation, the decision taken is to repair or to replace the deteriorate component. In the current legislation it’s stipulated that any repair, alteration or modification to an item of pressurised equipment that was originally post-weld heat treated after welding (PWHT) should be post-weld heat treated again after repair, requirement that cannot always be respected. For that reason, worldwide, there were developed various welding repair techniques without PWHT, among we find the Half Bead Technique (HBT) and Controlled Deposition Technique (CDT). The paper presents the experimental results obtained by applying the welding reconditioning techniques HBT and CDT in order to restore as quickly as possible the pressure vessels made of 13CrMo4-5. The effects of these techniques upon the heat affected zone are analysed, the graphics of the hardness variation are drawn and the resulted structures are compared in the two cases.

Effect of Welding Process on Microstructure, Mechanical and Pitting Corrosion Behaviour of 2205 Duplex Stainless Steel Welds

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

An attempt has been made to weld 2205 Duplex stainless steel of 6mm thick plate using conventional gas tungsten arc welding (GTAW) and activated gas tungsten arc welding (A- GTAW) process using silica powder as activated flux. Present work is aimed at studying the effect of welding process on depth of penetration, width of weld zone of 2205 duplex stainless steel. It also aims to observe the microstructural changes and its effect on mechanical properties and pitting corrosion resistance of 2205 duplex stainless steel welds. Metallography is done to observe the microstructural changes of the welds using image analyzer attached to the optical microscopy. Hardness studies, tensile and ductility bend tests were evaluated for mechanical properties. Potentio-dynamic polarization studies were carried out using a basic GillAC electro-chemical system in 3.5% NaCl solution to observe the pitting corrosion behaviour. Results of the present investigation established that increased depth of penetration and reduction of weld width in a single pass by activated GTAW with the application of SiO2 flux was observed when compared with conventional GTAW process. It may be attributed to the arc constriction effect. Microstructure of the weld zones for both the welds is observed to be having combination of austenite and delta ferrite. Grain boundary austenite (GBA) with Widmanstatten-type austenite (WA) of plate-like feature was nucleated from the grain boundaries in the weld zone of A-GTAW process. Mechanical properties are relatively low in activated GTAW process and are attributed to changes in microstructural morphology of austenite. Improved pitting corrosion resistance was observed for the welds made with A-GTAW process.

Physicochemical and toxicological characteristics of welding fume derived particles generated from real time welding processes.

PubMed

Chang, Cali; Demokritou, Philip; Shafer, Martin; Christiani, David

2013-01-01

Welding fume particles have been well studied in the past; however, most studies have examined welding fumes generated from machine models rather than actual exposures. Furthermore, the link between physicochemical and toxicological properties of welding fume particles has not been well understood. This study aims to investigate the physicochemical properties of particles derived during real time welding processes generated during actual welding processes and to assess the particle size specific toxicological properties. A compact cascade impactor (Harvard CCI) was stationed within the welding booth to sample particles by size. Size fractionated particles were extracted and used for both off-line physicochemical analysis and in vitro cellular toxicological characterization. Each size fraction was analyzed for ions, elemental compositions, and mass concentration. Furthermore, real time optical particle monitors (DustTrak™, TSI Inc., Shoreview, Minn.) were used in the same welding booth to collect real time PM2.5 particle number concentration data. The sampled particles were extracted from the polyurethane foam (PUF) impaction substrates using a previously developed and validated protocol, and used in a cellular assay to assess oxidative stress. By mass, welding aerosols were found to be in coarse (PM 2.5–10), and fine (PM 0.1–2.5) size ranges. Most of the water soluble (WS) metals presented higher concentrations in the coarse size range with some exceptions such as sodium, which presented elevated concentration in the PM 0.1 size range. In vitro data showed size specific dependency, with the fine and ultrafine size ranges having the highest reactive oxygen species (ROS) activity. Additionally, this study suggests a possible correlation between welders' experience, the welding procedure and equipment used and particles generated from welding fumes. Mass concentrations and total metal and water soluble metal concentrations of welding fume particles may be

Relationship between apposition pressure during welding and tensile strength of the acute weld

NASA Astrophysics Data System (ADS)

Wu, Paul J.; Walsh, Joseph T., Jr.

2001-05-01

Dye-assisted photothermal welding is a technique used to close wounds by thermally cross-linking collagen across apposed tissue edges. For a successful weld, not only do laser parameters have to be optimized, but also apposition of the incision has to be consistent and controlled. The objective of this study was to quantify the relationship between the applied apposition pressure (i.e., the compressive force holding the wound closed during the welding procedure divided by the area of the skin-to-skin interface) and the tensile strength of the wound following the welding procedure. By using a clamping device made of two complementary pieces, each 3 cm wide with a row of 10 equally spaced blunt wire mesh tips, the apposition pressure along a 2-cm-long incision in each albino guinea pig was quantified using a 127-micrometers -thick load cell and varied from 0-1.8 kgf/cm2. A continuous wave, Nd:YAG laser emitting 10.0 W of 1.06-micrometers radiation from a 600-micrometers -diameter fiber irradiating a 5-mm-diameter spot size was scanned across the incision in order to deliver 300 J of total energy. As the apposition pressure of the incisions was increased, the resulting tensile strength of welded skin increased in a sigmoidal manner. For this welding technique, an apposition pressure of at least 1.2 kgf/cm2 is necessary to obtain maximum weld strength of the skin (2.56+/- 0.36 kg/cm2).

49 CFR 195.214 - Welding procedures.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and...

49 CFR 195.214 - Welding procedures.

Code of Federal Regulations, 2014 CFR

2014-10-01

... 49 Transportation 3 2014-10-01 2014-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and...

49 CFR 195.214 - Welding procedures.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 3 2011-10-01 2011-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and...

49 CFR 195.214 - Welding procedures.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 49 Transportation 3 2013-10-01 2013-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and...

49 CFR 195.214 - Welding procedures.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 49 Transportation 3 2012-10-01 2012-10-01 false Welding procedures. 195.214 Section 195.214... PIPELINE Construction § 195.214 Welding procedures. (a) Welding must be performed by a qualified welder in accordance with welding procedures qualified under Section 5 of API 1104 or Section IX of the ASME Boiler and...

Deformation During Friction Stir Welding

NASA Technical Reports Server (NTRS)

White, Henry J.

2002-01-01

Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

Welding of gamma titanium aluminide alloys

NASA Technical Reports Server (NTRS)

Smashey, Russell W. (Inventor); Snyder, John H. (Inventor); Kelly, Thomas J. (Inventor); Sheranko, Ronald L. (Inventor)

1998-01-01

An article made of a gamma titanium aluminide alloy is welded, as for example in the weld repair of surface cracks, by removing foreign matter from the area to be welded, first stress relieving the article, cooling the entire article to a welding temperature of from about 1000.degree. F. to about 1400.degree. F., welding a preselected region in an inert atmosphere at the welding temperature, and second stress relieving the article. Welding is preferably accomplished by striking an arc in the preselected region so as to locally melt the alloy in the preselected region, providing a filler metal having the same composition as the gamma titanium aluminide alloy of the article, and feeding the filler metal into the arc so that the filler metal is melted and fused with the article to form a weldment upon solidification.

Repair welding of cast iron coated electrodes

NASA Astrophysics Data System (ADS)

Żuk, M.; Górka, J.; Dojka, R.; Czupryński, A.

2017-08-01

Welding cast iron is a complex production procedure. Repair welding was used to repair damaged or poorly made castings. This is due to a tendency to cracking of the material during welding as well as after it. Welding cast iron can be carried out on hot or on cold. Hot welding requires high heat material and the use of welding material in the form of cast iron. In the case of cold welding, it is possible to use different materials. Mostly used filler metals are nickel and copper based. The work shows the course of research concerning repairmen of ductile iron with arc welding method. For the reparation process four types of ESAB company coated electrodes dedicated for cast iron were used with diameter 3.2 and 4 mm: ES 18-8-6B (4mm), EB 150 (4mm), OK NiCl, EŻM. In the cast iron examined during the testing grooves were made using plasma methods, in order to simulate the removed casting flaws. Then the welding process with coated electrodes was executed. The process utilized low welding current row of 100A, so there would only be a small amount of heat delivered to the heat affected zone (HAZ). Short stitches were made, after welding it was hammered, in order to remove stresses. After the repair welding the part of studies commenced which purpose was finding surface defects using visual testing (VT) and penetration testing (PT). In the second part, a series of macro and microscopic studies were executed witch the purpose of disclosuring the structure. Then the hardness tests for welds cross sections were performed. An important aspect of welding cast iron is the colour of the padding weld after welding, more precisely the difference between the base material and padding weld, the use of different materials extra gives the extra ability to select the best variant. The research of four types of coated electrode was executed, based on the demands the best option in terms of aesthetic, strength and hardness.

49 CFR 195.234 - Welds: Nondestructive testing.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Welds: Nondestructive testing. 195.234 Section 195... HAZARDOUS LIQUIDS BY PIPELINE Construction § 195.234 Welds: Nondestructive testing. (a) A weld may be... weld. (b) Any nondestructive testing of welds must be performed— (1) In accordance with a written set...

49 CFR 192.235 - Preparation for welding.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 49 Transportation 3 2010-10-01 2010-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material that...

49 CFR 192.235 - Preparation for welding.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 49 Transportation 3 2011-10-01 2011-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material that...

49 CFR 192.235 - Preparation for welding.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 49 Transportation 3 2012-10-01 2012-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material that...

49 CFR 192.235 - Preparation for welding.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 49 Transportation 3 2013-10-01 2013-10-01 false Preparation for welding. 192.235 Section 192.235... BY PIPELINE: MINIMUM FEDERAL SAFETY STANDARDS Welding of Steel in Pipelines § 192.235 Preparation for welding. Before beginning any welding, the welding surfaces must be clean and free of any material that...

49 CFR 192.235 - Preparation for welding.